Tampon Method Of Manufacture

ABSTRACT

A pledget for a tampon having improved leakage prevention of bodily fluid after the tampon is inserted in the vagina. The pledget can have an absorbent structure having two layers. At least one of the layers of the absorbent structure can have one contact element at least partially separated from a second contact element. A method of manufacturing the tampon can include a step of incorporating a contact element into at least one of the two layers of the absorbent structure.

BACKGROUND

Currently, there are two basic types of tampons used for femininehygiene. The first type is a digitally insertable tampon which isdesigned to be inserted directly by the user's fingers. The second typeis an applicator style tampon which is designed to be inserted with theaid of an applicator. Both types are usually made by folding or rollingrectangular strips of absorbent material into a blank and thencompressing the blank into a cylindrically-shaped pledget. The pledgetmay or may not have a cover. In both types, a withdrawal string can beattached to the pledget. The combination of a pledget and a withdrawalstring is considered a useable tampon product. The tampon can then bewrapped and packaged for sale. In the applicator style tampon, thetampons can be assembled into an applicator prior to being wrapped andpackaged.

Tampons work by acquiring vaginal fluids, including menses, at theinterface between the tampon and vaginal wall. To ensure this contact,current tampons alter the vagina immediately upon insertion. Thisalteration contributes to early premature, “by-pass” leakage. After thetampon absorbs the vaginal fluids, including menses, most tampons beginto expand uniformly and globally, further contributing to this leakage.At the same time, the tampon begins to become more flexible andconformable to allow for a better global/macro fit to the vagina. Thispredetermined and uniform tampon response that drives this global/macroexpansion is governed by the tampon construction and materials.

Even when fluid is acquired locally and the deformational forces on thetampon by the vaginal environment are applied locally, with currenttampons the construction or materials of the tampons inhibits orconstrains their capacity to expand or adapt to give a local/micro fit.These constructions and materials force the entire tampon to respond tothese local fluid acquisition and deformational forces through materialconnectivity or material stiffness.

When attempts are made to allow for more local adaptation in tamponconstructions, the constructions do not acquire the fluids well becauseof inadequate contact area because they cannot match the local contoursof the vaginal wall or are not conformable enough to adapt to thewomen's individual local contours (e.g. folds and convolutions) found onthe vaginal wall. In addition, these attempts create integrity issueswith the tampons that lead to portions of the tampon remaining withinthe vagina after tampon removal. This inadequate contact is especiallytrue during the wiping action of the vagina by the tampon when thetampon is inserted and removed.

Current tampon construction processes construct these inadequate tamponsthat have this predetermined and uniform tampon response. They createthese constraints, inadequate contact area, and integrity issues inorder to drive this predetermined and uniform tampon response and,therefore, limit the tampon from effectively responding locally. Newconstruction processes will be needed to construct tampons that overcomethe inadequacy of current tampons.

There remains a need for a tampon that responds locally to meet theindividual protection needs of women and processes to make such tampons.There remains a need for a tampon that prevents leakage of body fluidafter being inserted into a woman's vagina. There remains a need for atampon that provides efficient utilization of the entire tamponstructure during use. There remains a need for a tampon that provides acustomized fit to the anatomy of a woman's vaginal cavity. There remainsa need for a tampon that can deform and come into contact with the foldsand convolutions of the walls of the vaginal cavity and acquire anycontacted fluid.

SUMMARY

A method of manufacturing a pledget can have the steps of providing afirst layer of fibrous material; providing a second layer of fibrousmaterial; bonding the first layer and the second layer to each other tocreate an absorbent structure; incorporating at least two contactelements into at least one of the first layer and the second layer toform a contact element; and compressing the absorbent structure into apledget. In an embodiment, the method can further comprise the step offorming a nonwoven ribbon comprising the first layer and the secondlayer. In an embodiment, the method can further comprise the step ofseparating at least one individual unit of fleece from the nonwovenribbon. In an embodiment, the method can further comprise the step ofrolling, stacking, or folding the individual unit of fleece. In anembodiment, the method can further comprise the step of incorporating afold into at least one of the first layer and the second layer offibrous material. In an embodiment, the method can further comprise thestep of providing a cover. In an embodiment, the first layer can have afirst transverse edge and a second transverse edge and the second layercan have a first transverse edge and a second transverse edge. In anembodiment, a step of bonding the first layer and the second layer toeach other can further comprise the step of aligning one of the firsttransverse edge and the second transverse edge of the first layer to oneof the first transverse edge and the second transverse edge of thesecond layer. In an embodiment, the step of incorporating at least twocontact elements can further comprise the step of at least partiallyseparating the at least two contact elements. In an embodiment, the atleast two contact elements can be separated by a slit. In an embodiment,the at least two contact elements can be separated by an amplitude of anarc. In an embodiment, the step of incorporating at least two contactelements can further comprise the step of associating at least one ofthe two contact elements with at least one of the first and secondtransverse edges of at least one of the first layer and the second layerof fibrous material. In an embodiment, the step of incorporating atleast two contact elements can further comprise the step ofincorporating at least one of the contact elements at a location betweenat least one of the first and second transverse edges of at least one ofthe first layer and the second layer of fibrous material. In anembodiment, the step of incorporating at least two contact elements canfurther comprise the step of associating at least one of the contactelements with the fold.

A method of manufacturing a nonwoven ribbon can comprise the steps ofproviding a first layer of fibrous material; incorporating at least twocontact elements into the first layer of fibrous material; providing asecond layer of fibrous material; and bonding the first layer of fibrousmaterial to the second layer of fibrous material. In an embodiment, themethod can further comprise the step of incorporating a fold into atleast one of the first layer and the second layer of fibrous material.In an embodiment, the step of incorporating the at least two contactelements further comprises the step of associating at least one of thecontact elements with the fold. In an embodiment, the step ofincorporating at least two contact elements can further comprise thestep of incorporating at least one slit into at least one of the firstlayer and the second layer of fibrous material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of a tampon in acompressed configuration.

FIG. 2 is a perspective view of an embodiment of a nonwoven ribbon.

FIG. 3 is a perspective view of an embodiment of a fleece.

FIG. 4 is a perspective view of an embodiment of an absorbent structure.

FIG. 5 is a perspective view of an embodiment of an absorbent structure.

FIG. 6 is a perspective view of an embodiment of an absorbent structure.

FIG. 7 is a perspective view of an embodiment of an absorbent structure.

FIG. 8 is a perspective view of an embodiment of an absorbent structure.

FIG. 9 is a side view of an embodiment of an absorbent structure.

FIG. 10 is a perspective view of an embodiment of a tampon in anactivated configuration.

FIG. 11 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 12 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 13 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 14 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 15 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 16 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 17 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 18 is a side view of an embodiment of an absorbent structure.

FIG. 19 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 20 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 21 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 22 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 23 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 24 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 25 is a perspective view of an embodiment in which a cover isbonded to a blank.

FIG. 26A is an end view of an embodiment in which a cover is bonded to ablank.

FIG. 26B is an end view of an embodiment in which a cover is bonded to ablank.

FIG. 27 is a side view of an embodiment of a tampon wherein the coverdefines a skirt.

FIG. 28 is a perspective view of an embodiment of a tampon in anactivated configuration.

FIG. 29 is a perspective view of an embodiment of a method ofmanufacturing an absorbent structure.

FIG. 30 is a perspective view of an embodiment of a method ofmanufacturing an absorbent structure.

DETAILED DESCRIPTION

The tampon of the current disclosure can be inserted above the introitalregion of a woman's vagina, can intercept the fluid flow of menses,blood, and other body fluids, and can prevent the fluid from exiting thevagina. While the pledgets and tampons of the current disclosure aredescribed for use as a menstrual device, it will be readily apparentthat the pledgets and tampons can also be used as any other suitablevaginal insert, such as a pessary. Likewise, while the pledgets andtampons of the current disclosure are generally described as being“absorbent,” it will be readily apparent that the pledgets and tamponsmay be coated or otherwise treated to be partially or completelynon-absorbent.

In an embodiment, the pledget and tampon of the current disclosure canhave a contact element. In an embodiment, the contact element can allowthe pledget and the tampon to respond locally to the changes in thevaginal environment and can effectively acquire fluid locally toaccommodate the uniqueness of a woman's vaginal environment and herperiod.

A non-limiting embodiment of a tampon 10 of the current disclosure isillustrated in FIG. 1. The tampon 10 can be inserted into a woman'svaginal cavity to prevent menses from exiting the vaginal opening bycontacting and absorbing the flow of menses. The term “menses,” as usedherein, includes blood, tissue debris, and other bodily fluids emittedfrom the vaginal opening. The tampon 10 can have a compressed, generallycylindrical shaped pledget 12 and a withdrawal aid 14. In someembodiments, the generally cylindrical shape of the pledget 12 can havea cross-section that can be at least one of an oval, circle, square,rectangle, or any other cross-sectional shape known in the art. The term“cross-section” refers herein to the plane which extends laterallythrough the tampon 10, and which is orthogonal to the longitudinal axis16 of the pledget 12, and consequently, of the tampon 10. The tampon 10can have an insertion end 18 and a withdrawal end 20. The tampon 10 canhave a length 22 wherein the length 22 is the measurement of the tampon10 along the longitudinal axis 16 originating at one end (insertion orwithdrawal) of the tampon 10 and ending at the opposite end (insertionor withdrawal) of the tampon 10. In some embodiments, the tampon 10 canhave a length 22 from about 30 mm to about 80 mm. The tampon 10 can havea width 24, which unless otherwise stated herein, can correspond to thegreatest cross-sectional dimension along the longitudinal axis 16 of thetampon 10. In some embodiments, the tampon 10 can have a compressedwidth 24 prior to usage from about 2, 5, 8, 10, 12, or 14 mm to about 20or 30 mm. The tampon 10 may be straight or non-linear in shape, such ascurved along the longitudinal axis 16.

As noted above, the tampon 10 can have a pledget 12. The pledget 12 canbe formed from a blank 28, such as a softwind, wherein the blank 28 canbe formed from a fleece 30. The fleece 30 can have an absorbentstructure 34 which can be a single layer of a fibrous material or can bemultiple layers of fibrous material. In an embodiment, an absorbentstructure 34 can be formed of at least two layers of fibrous materials.The absorbent structure 34 can be manufactured via processes such as,for example, a multi-bank laydown, bonding pre-formed layers together,or a combination thereof. Such processes can produce a nonwoven ribbon32 having an absorbent structure 34 of a single layer or multiple layersof fibrous materials. In an embodiment, the nonwoven ribbon 32 can beseparated into individual units of fleece 30, wherein each unit offleece 30 can have the absorbent structure 34.

In an embodiment in which the absorbent structure 34 is multi-layered,the absorbent structure 34 can have at least 2, 3, 4, 5, 6, or 7 layersof fibrous material. In an embodiment in which the absorbent structure34 is multi-layered, a layer can be identical to another layer, can bedifferent from another layer, or can be identical to at least one otherlayer and can be different from at least one other layer. In anembodiment in which an absorbent structure 34 is multi-layered and atleast one layer is different from another layer, the layers can bedifferent from each other by at least 1, 2, 3, 4 or 5 aspects.Non-limiting examples of aspects of differences can include density,thickness, type of fibrous material in a layer, amount of fibrousmaterial in a layer, hydrophilic/hydrophobic characteristics, andstrength/integrity characteristics (which can include reinforcingfibrous materials).

In an embodiment in which the absorbent structure 34 is multi-layered,the absorbent structure 34 can be manufactured by bonding at least twopre-formed layers together. In such an embodiment, the pre-formed layerscan be brought into contact with each other and bonded together by anysuitable method. In such an embodiment, the bonded layers can then bebonded to at least one additional layer. The at least one additionallayer can be pre-formed or can be a laid down fibrous material.

In an embodiment in which the absorbent structure 34 is multi-layered,the absorbent structure 34 can be manufactured via a process such as amulti-bank fibrous material laydown. In such a process, fibrous materialin a first bank can be laid down to form a first layer and fibrousmaterial in a second bank can be laid down onto the first layer andformed into a second layer. The second layer can then, if desired, bebonded to the first layer. In an embodiment, fibrous material in atleast one additional bank can be laid down onto the prior layers andformed into at least one additional layer if so desired. The additionallayer(s) can be bonded to the prior formed and bonded layers. In anembodiment, a pre-formed layer can be bonded to the formed and bondedlayers.

FIG. 2 provides a non-limiting illustration of a nonwoven ribbon 32which can have a multi-layer absorbent structure 34 of at least twolayers, such as layers 36 and 38. The nonwoven ribbon 32 can bemanufactured via either a multi-bank fibrous material laydown method,via bonding of pre-formed layers, or via a combination of the describedmethods. It is to be understood that while the description and figuresherein generally illustrate a nonwoven ribbon 32, an absorbent structure34 and/or a fleece 30 having two layers, such as layers 36 and 38, anonwoven ribbon 32, an absorbent structure 34 and/or a fleece 30 canhave more than two layers and the description herein is applicable to anonwoven ribbon 32, an absorbent structure 34 and/or a fleece 30 havingmore than two layers.

In an embodiment, the nonwoven ribbon 32 can have more than two layers.In an embodiment, a layer(s), such as layer(s) 36 and/or 38, can behydrophobic or hydrophilic. In an embodiment, a layer(s), such aslayer(s) 36 and/or 38, can be treated with a surfactant or othermaterial to make the layer(s) hydrophilic or to make the layer(s) morehydrophilic. As will be described herein, in a nonwoven ribbon 32 havingmore than one layer, the layers, such as layers 36 and 38, can be incommunication with each other. In an embodiment, the layers, such aslayers 36 and 38, can be in communication with each other and can bebonded to each other. The terms “bonded” or “bonding” refer herein tothe joining, adhering, connecting, attaching or the like of twoelements. Two elements will be considered bonded together when they arejoined, adhered, connected, or attached directly to one another orindirectly to one another, such as when each is directly joined,adhered, connected or attached to intermediate elements. The bonding canoccur by any method deemed suitable including, but not limited to,adhesives, heat bonding, vibration energy, mechanical bonding, chemicalbonding, vacuum bonding, ultrasonic bonds, thermal bonds, pressurebonds, mechanical entanglement, hydroentanglement, microwave bonds, orany other conventional technique. The bonding can be continuous or itcan be intermittent.

Each layer, such as layers 36 and 38, can be constructed from fibrousmaterials, such as fibrous materials 40 and 42, respectively. In anembodiment, the fibrous materials can include absorbent fibers. Thefibrous materials can include, but are not limited to, natural andsynthetic fibers such as, but not limited to, polyester, acetate, nylon,cellulosic fibers such as wood pulp, cotton, rayon, viscose, LYOCELL®such as from Lenzing Company of Austria, or mixtures of these or othercellulosic fibers. Natural fibers can include, but are not limited to,wool, cotton, flax, hemp and wood pulp. Wood pulps can include, but arenot limited to, standard softwood fluffing grade such as CR-1654 (USAlliance Pulp Mills, Coosa, Ala.). Pulp may be modified in order toenhance the inherent characteristics of the fibers and theirprocessability. Crimping can be imparted to the fibers by any meansdeemed suitable by one of ordinary skill Curl may be imparted to thefibers by suitable methods such as, for example, chemical treatment ormechanical twisting. Curl can be imparted before crosslinking orstiffening. Pulps may be stiffened by the use of crosslinking agentssuch as formaldehyde or its derivatives, glutaraldehyde,epichlorohydrin, methylated compounds such as urea or urea derivatives,dialdehydes such as maleic anhydride, non-methylated urea derivatives,citric acid or other polycarboxylic acids. Pulp may also be stiffened bythe use of heat or caustic treatments such as mercerization. Examples ofthese types of fibers include NHB416, which is a chemically cross-linkedsouthern softwood pulp fiber which enhances wet modulus, available fromWeyerhaeuser Corporation of Tacoma, Wash. Other non-limiting examples ofuseful pulps are debonded pulp (NF405) and non-debonded pulp (NB416)also from Weyerhaeuser. HPZ3 from Buckeye Technologies, Inc. of Memphis,Tenn., is an example of a fiber that has a chemical treatment that setsin a curl and twist, in addition to imparting added dry and wetstiffness and resilience to the fiber. Another suitable pulp is BuckeyeHP2 pulp and still another is IP Supersoft from International PaperCorporation. The fibrous materials can include any suitable blend offibers. For example, the fibrous materials can be formed from cellulosefibers such as cotton and rayon. The fibrous materials can be 100 wt %cotton, 100 wt % rayon, or a blend of cotton and rayon. In someembodiments, the cellulose fibers may be modified for super-absorbency.In an embodiment, a layer, such as layer 36 or 38, can havesubstantially the same fibrous material composition as another layer,such as layer 36 or 38. In an embodiment, a layer, such as layer 36 or38, can have a fibrous material composition different from anotherlayer, such as layer 36 or 38.

In an embodiment, the fibrous materials can have a staple length of fromabout 5, 10, 15 or 20 mm to about 30, 40 or 50 mm. In an embodiment, thefibrous materials can have a fiber size of from about 15 microns toabout 28 microns. In an embodiment, the fibrous materials can have adenier of from about 1 or 2 to about 6. Denier is a unit of fineness ofyarn based on a standard of 50 milligrams (mg) for 450 meters of yarn.The fibrous materials can have a circular, bi-lobal or tri-lobalcross-sectional configuration or any other configuration known to thoseskilled in the art. A bi-lobal configuration can have a cross-sectionalprofile which can look like a dog bone while a tri-lobal configurationcan have a cross-sectional profile which can look like a “Y.” In anembodiment, the fibrous materials can be bleached. In an embodiment, thefibrous materials can have a color.

In an embodiment, a layer(s), such as layer(s) 36 and/or 38, can containfibrous materials such as binder fibers. In an embodiment, the binderfibers can have a fiber component which can bond or fuse to other fibersin the layer. Binder fibers can be natural fibers or synthetic fibers.Synthetic fibers can include, but are not limited to, those made frompolyolefins, polyamides, polyesters, rayon, acrylics, viscose,superabsorbents, LYOCELL® regenerated cellulose and any other suitablesynthetic fiber known to those skilled in the art. Non-limiting examplesof polyolefins can include, but are not limited to, polyethylene such asDow Chemical's ASPUN® 6811A linear low density polyethylene, 2553 LLDPEand 25355 and 12350 high density polyethylene. The polyethylenes canhave melt flow rates, respectively, of about 26, 40, 25, and 12.Non-limiting examples of fiber forming polypropylenes can include, butare not limited to, Exxon Chemical Company's ESCORENE® PD 3445polypropylene and Montell Chemical Company's PF304. Another example of afiber can be a bi-component polyethylene sheath and polyester core knownas T255 made by Trevira of Germany. Other non-limiting examples ofmeltable bicomponent fibers can include, but are not limited to, fibersavailable from Unitika of Japan, such as, for example, Unitika MELTY4080, and 6080 fibers, having either polyester sheaths or cores andpolyethylene sheaths or cores. Another example can include, but is notlimited to, fibers available from Fibervisions under the designation ETCBounce fiber line, such as PET/PE fibers of about 2.2 decitex and about40 mm staple fiber length. Non-limiting examples of rayon fibers include1.5 denier Merge 18453 fibers from Accordis Cellulose Fibers Inc. ofAxis, Ala. The fibrous materials can be treated by conventionalcompositions and/or processes to enable or enhance wettability.

In an embodiment, a layer(s), such as layer(s) 36 and/or 38, can containfibrous materials such as cellulosic fibers, such as cotton and rayon.In an embodiment, a layer(s), such as layer(s) 36 and/or 38, can be 100%cotton, 100% rayon, or a blend of cotton and rayon fibers. In anembodiment, a blend of cotton and rayon fibers can be a blend of about15% cotton and about 85% rayon; about 70% cotton and about 30% rayon;about 60% cotton and about 40% rayon; about 25% cotton and about 75%rayon; or a blend of about 6% cotton and about 94% rayon. The blend ofcotton and rayon can be any blend as deemed suitable. In an embodiment,additional fibers such as polyester or other synthetic fibers can beadded to the blend of cotton and rayon to add resilient features orbondability to a layer(s), such as layer(s) 36 and/or 38.

In an embodiment, a layer(s), such as layer(s) 36 and/or 38, can have ablend of viscose and binder fibers. In an embodiment, a blend of viscoseand binder fibers can be a blend of from about 70% viscose to about 95%viscose with the remainder from about 30% to about 5% binder fiber. Inan embodiment, a blend of viscose and binder fibers can be a blend offrom about 85-90% viscose and the remainder from about 15-10% binderfiber. The blend of viscose and binder fibers can be any blend as deemedsuitable.

Various methods known to those skilled in the art can be used to prepareeach layer, such as layers 36 and 38. Such methods can include, but arenot limited to, airlaying, carding, wetlaying, needlepunching,mechanical entanglement, hydroentangling, and any other known methoddeemed suitable by one of ordinary skill. In an embodiment, a bondedcarded web can be made from staple fibers. In such an embodiment, thefibers can be longer than about 20, 30 or 35 mm. The fibers can bepurchased in bales which can be placed in a picker to separate thefibers. The fibers can then be sent through a combing or carding unit,which can further break apart and align the staple fibers in the machinedirection to form a generally machine direction-oriented fibrousnonwoven web. Once the web is formed, it can then be bonded by one ormore of several known bonding methods, such as through air bonding orpattern bonding. In an embodiment, a dry laid web can be made fromstaple fibers. In such an embodiment, the fibers can be about 20 mm orlonger. In dry laying, fibers or tufts of fibers of a first type (e.g.,absorbent fibers and/or binder fibers) can be fed to a first rotatingvacuum drum and fibers or tufts of fibers of a second type (e.g.,absorbent fibers and/or binder fibers) can be fed to a second rotatingvacuum drum. The fibers can then be laid down by suction to form mats offibers. The mats of fibers can be doffed from the vacuum drums andcombed via rotating lickerins. The lickerins can have peripheral teethwhich can comb the fibers from the mat. The combed fibers can be doffedfrom the lickerins via centrifugal force and placed into a fiber mixingand expansion chamber. The mixed fibers can be placed on a vacuum screento form a random fiber web comprising the first and second fiber types.The flow and velocity of each independent fiber stream can be controlledto provide the desired quantity of each fiber type. It is to beunderstood that a layer, such as layer 36 or 38, can be prepared usingthe same method as another layer, such as layer 36 or 38, or using amethod different than another layer, 36 or 38.

In an embodiment, at least one of the layers, such as layers 36 and/or38, can be prepared using an airlaying process. In such an embodiment,the airlaid fibers can contain a first fiber and a second fiber, whereinthe first fiber can be a binder fiber and the second fiber can be anabsorbent fiber.

In an embodiment in which binder fibers are present, the binder fiberscan be activated to create a three-dimensional fiber matrix. In such anembodiment, the activation can be completed by any suitable heating stepincluding, but not limited to, convection heating, through air heating,superheated steam, microwave heating, radiant heating, radio frequencyheating, and the like, and combinations thereof. In some embodiments,the activation can be accomplished by heating the layer(s), such aslayer(s) 36 and/or 38, containing the binder fibers at a temperature offrom about 240° F. to about 330° F. (about 115 to about 165° C.) toactivate the binder fibers. It is to be understood that the bondingtemperature selected should be selected based upon the fibrous materialswhich are being bonded together. Without being bound by theory, it isbelieved that during activation, the binder fibers can soften and becometacky and, therefore, bind to adjacent fibers creating athree-dimensional fiber matrix. It is believed that thethree-dimensional fiber matrix can stabilize the layer(s), such aslayer(s) 36 and/or 38, and can create a liquid stable network. It is tobe understood that an additional component or finish can be added to thefibers to facilitate bonding of fibrous materials which are notnecessarily compatible.

In an embodiment, the activation can be followed by a cooling step whichcan utilize any suitable means for reducing the temperature of thelayer(s), such as layer(s) 36 and/or 38. In an embodiment, the layer(s),such as layer(s) 36 and/or 38, can be cooled by allowing the layer(s),such as layer(s) 36 and/or 38, to return to ambient temperature over aperiod of time. In an embodiment, the layer(s), such as layer(s) 36and/or 38, can be cooled by chill rolls, cooling chambers, blowingconditioned air, or the like, and combinations thereof. In anembodiment, the cooling step can occur prior to compression of thelayer(s), such as layer(s) 36 and/or 38, to establish a wet-stablethree-dimensional structure.

In some embodiments, a layer(s), such as layer(s) 36 and/or 38, can befurther manipulated such as, for example, being folded, corrugated, orotherwise processed.

The nonwoven ribbon 32 can be separated into individual units of fleece30. The separation of the nonwoven ribbon 32 into individual units offleece 30 can occur by any suitable method such as stretching,perforating, cutting such as with the use of a die cutter or a knifecutter, and the like. The individual units of fleece 30 can then berolled, stacked, folded, or otherwise manipulated into blanks 28. Theblanks 28 can then be formed into pledgets 12 in any manner deemedsuitable. As a non-limiting example, the blanks 28 can undergocompression to form the pledgets 12.

In various embodiments, the fleece 30 and the resultant pledget 12 canhave any suitable combination and ratio of fibrous material. In anembodiment, the fleece 30 and the resultant pledget 12 can have fromabout 70 to about 95 wt % absorbent fibers and from about 5 to about 30wt % binder fibers. In an embodiment, the fleece 30 and the resultantpledget 12 can have from about 80 to about 90 wt % absorbent fibers andfrom about 10 to about 20 wt % binder fibers. In an embodiment, thefleece 30 and the resultant pledget 12 can have about 85 wt % absorbentfibers and about 15 wt % binder fibers. In an embodiment, the fleece 30and the resultant pledget 12 can have from about 80 to about 90 wt %trilobal viscose rayon fibers and from about 10 to about 20 wt %bicomponent binder fibers. In an embodiment, the fleece 30 and theresultant pledget 12 can have about 85 wt % trilobal viscose rayonfibers and about 15 wt % bicomponent binder fibers. In an embodiment,the fleece 30 and the resultant pledget 12 can have greater than about50, 55, 60, 65, 70, 80, 90, 95, 97, or 99 wt % absorbent fibers.

The fleece 30 can be any size and thickness that can ultimately becompressed into a pledget 12 having a vaginally insertable shape. In anembodiment, the size of the fleece 30 can range from about 40 mm toabout 100, 200, 250 or 300 mm in width and from about 30 mm to about 80mm in length. As described herein, the width of the fleece 30 can bemeasured as the distance between longitudinal edges of the fleece 30 andthe length of the fleece 30 can be measured as the distance betweentransverse edges of the fleece 30. As described herein, the transverseedges of the fleece 30 can be located at the insertion and withdrawalends, 18 and 20, respectively, of a resultant tampon 10. In anembodiment, the overall basis weight of the fleece 30 can range fromabout 15, 20, 25, 50, 75, 90, 100, 110, 120, 135 or 150 gsm to about1,000, 1,100, 1,200, 1,300, 1,400, or 1,500 gsm.

Referring to FIG. 3, a non-limiting example of a fleece 30 isillustrated in which the fleece 30 can have a multi-layer absorbentstructure 34 of two layers, 36 and 38. In the non-limiting exampleillustrated, the first layer 36 can have a first length 44 and a firstwidth 46. The first length 44 can extend from a first transverse edge 48to a second transverse edge 50 of the first layer 36. The first width 46can extend from a first longitudinal edge 52 to a second longitudinaledge 54 of the first layer 36. The first layer 36 can have a firstsurface 56 (illustrated in FIG. 4) and a second surface 58. Similarly,the second layer 38 can have a second length 60 and a second width 62.The second length 60 can extend from a first transverse edge 64(illustrated in FIG. 4) to a second transverse edge 66 of the secondlayer 38. The second width 62 can extend from a first longitudinal edge68 to a second longitudinal edge 70 of the second layer 38. The secondlayer 38 can have a first surface 72 and a second surface 74(illustrated in FIG. 4). In a resultant tampon 10, the transverse edgesof each layer, 36 and 38, can be located at the insertion end 18, thewithdrawal end 20 or, as described herein, a location between theinsertion end 18 and the withdrawal end 20. As a non-limiting examplewith regards to the fleece 30 illustrated in FIG. 3, transverse edges 50and 66 can be located at the insertion end 18 of a resultant tampon 10and transverse edges 48 and 64 can be located at the withdrawal end 20of a resultant tampon 10.

The absorbent structure 34 can be constructed such that one of thesurfaces, 56 or 58, of the first layer 36 can be at least partially in aface to face relationship with one of the surfaces, 72 or 74, of thesecond layer 38. In an embodiment, at least about 25% of one of thesurfaces, 72 or 74, of the second layer 38 can be in a face to facerelationship with one of the surfaces, 56 or 58, of the first layer 36.In an embodiment, at least about 25, 30, 35, 40, 45, 50, 55, 60, 65, 70,75, 80, 85, 90, 95 or 100% of one of the surfaces, 72 or 74, of thesecond layer 38 can be in a face to face relationship with one of thesurfaces, 56 or 58, of the first layer 36. In an embodiment, less than100% of one of the surfaces, 72 or 74, of the second layer 38 can be ina face to face relationship with one of the surfaces, 56 or 58, of thefirst layer 36. In an embodiment, from about 25, 30, 35, 40, 45, or 50%to about 55, 60, 65, 70, 75, 80, 85, 90, 95 or 100% of one of thesurfaces, 72 or 74, of the second layer 38 can be in a face to facerelationship with one of the surfaces, 56 or 58, of the first layer 36.

In the exemplary illustration of FIG. 3, the first and second layers, 36and 38, are illustrated as being substantially coextensive with eachother. In such an embodiment, the first length 44 of the first layer 36can be substantially the same as the second length 60 of the secondlayer 38. The first width 46 of the first layer 36 can be substantiallythe same as the second width 62 of the second layer 38. In the exemplaryillustration of FIG. 3, about 100% of the first surface 56 of the firstlayer 36 can be in a face to face relationship with the second surface74 of the second layer 38. As described herein, a withdrawal aid 14 anda cover 138 can be associated with the fleece 30.

In an embodiment, the fleece 30 can have a multi-layer absorbentstructure 34 in which one of the layers, 36 or 38, can have a lengthand/or width different from the other layer, 36 or 38. Referring toFIGS. 4-8, non-limiting examples of embodiments of absorbent structures34 are illustrated in which one layer, 36 or 38, can have a lengthand/or width different from the other layer, 36 or 38.

FIG. 4 provides an illustration of a non-limiting example of anembodiment of a multi-layer absorbent structure 34 in which the firstlayer 36 can have a first width 46 greater than the second width 62 ofthe second layer 38. As illustrated in FIG. 4, the first length 44 ofthe first layer 36 can be substantially similar to the second length 60of the second layer 38. In the non-limiting example illustrated in FIG.4, the second layer 38 can be bonded to the central region of the firstwidth 46 of the first layer 36. The central region of the first width 46can be the area adjacent a center line 78 of the first width 46 of thefirst layer 36 of the absorbent structure 34. It is to be understoodthat the central region of the first width 46 does not need to be theexact center of the first layer 36, but can be located generally aroundthe center line 78 of the first width 46. In an embodiment, the centralregion of the first width 46 of the first layer 36 can be a positionalong the first width 46 which is a distance 80 that is about 0.35 toabout 0.65 times the first width 46, as measured from eitherlongitudinal edge, 52 or 54, of the first layer 36. It is to beunderstood that the second layer 38 does not have to be bonded to thefirst layer 36 in the central region of the first width 46, but rathercould be bonded to the first layer 36 in an area adjacent to one of thelongitudinal edges, 52 or 54, or at any other position along the firstwidth 46 of the first layer 36 as deemed suitable.

FIG. 5 provides an illustration of a non-limiting example of anembodiment of a multi-layer absorbent structure 34 in which the firstlayer 36 can have a first length 44 greater than the second length 60 ofthe second layer 38. As illustrated in FIG. 5, the first width 46 of thefirst layer 36 can be substantially similar to the second width 62 ofthe second layer 38. In the non-limiting example illustrated in FIG. 5,the second layer 38 can be bonded adjacent to one of the transverseedges, 48 or 50, such as transverse edge 50, of the first layer 36. Itis to be understood that the second layer 38 can be bonded to the firstlayer 36 at any position along the first length 44 of the first layer 36as deemed suitable.

FIG. 6 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 in which the first layer 36 canhave a first length 44 greater than the second length 60 of the secondlayer 38. As illustrated in FIG. 6, the first width 46 of the firstlayer 36 can be substantially similar to the second width 62 of thesecond layer 38. In the non-limiting example illustrated in FIG. 6, thesecond layer 38 can be bonded in the central region of the first length44 of the first layer 36. The central region of the first length 44 canbe the area adjacent a center line 84 of the first length 44 of thefirst layer 36 of the absorbent structure 34. It is to be understoodthat the central region of the first length 44 does not need to be theexact center of the first layer 36, but can be located generally aroundthe center line 84 of the first length 44. In an embodiment, the centralregion of the first layer 36 can be a position along the first length 44which can be a distance 86 that can be about 0.35 to about 0.65 timesthe first length 44, as measured from either transverse edge, 48 or 50,of the first layer 36. In an embodiment, the second layer 38 does nothave to be bonded to the first layer 36 in the central region of thefirst length 44, but rather could be bonded to the first layer 36 in anarea adjacent to one of the transverse edges, 48 or 50, or at any otherposition along the first length 44 of the first layer 36 as deemedsuitable.

FIG. 7 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 in which the first layer 36 isillustrated as having a first length 44 and a first width 46 that areeach greater than the second length 60 and the second width 62 of thesecond layer 38.

FIG. 8 provides an illustration of a non-limiting example of anabsorbent structure 34 in which less than 100% of surface 74 of secondlayer 38 can be in a face to face relationship with surface 56 of firstlayer 36. First width 46 can be substantially similar to second width62, however it should be realized that first width 46 can be greaterthan or less than second width 62. First length 44 can be greater than,less than, or substantially similar to second length 60.

In an embodiment in which a layer, such as layer 36 or 38, has a lengthand/or width smaller than a length and/or width of another layer, suchas layer 36 or 38, the layer with the smaller dimension can be bonded tothe layer with the larger dimension in any location as deemed suitable.

FIGS. 4-8 provide non-limiting illustrations in which the second layer38 can be positioned on top of the first layer 36. In an embodiment, thefirst layer 36 can be positioned on top of the second layer 38. In anembodiment, at least a portion of a layer, such as layer 36 or 38, canbe inset into another layer, such as layer 36 or 38. In an embodiment,all of a layer, such as layer 36 or 38, can be inset into another layer,such as layer 36 or 38. FIG. 9 provides a non-limiting example of anembodiment of an absorbent structure 34 in which at least a portion ofthe second layer 38 can be at least partially inset into the first layer36.

As described herein, each layer, such as layers 36 and 38, can havetransverse edges, such as transverse edges 48 and 50 of layer 36 andtransverse edges 64 and 66 of layer 38. In an embodiment, eachtransverse edge(s), 48, 50, 64 and/or 66, can be linear, non-linear,arcuate, and any combination thereof as deemed suitable. Such an edgecan be produced in any manner as deemed suitable, such as, but notlimited to, knife cutting, die cutting, or any other method known to oneskilled in the art. As described herein, a transverse edge can belocated at the insertion end 18, the withdrawal end 20 or a locationbetween the insertion and withdrawal ends, 18 and 20, of a resultanttampon 10.

In an embodiment, at least one layer, such as layer(s) 36 and/or 38, ofthe absorbent structure 34 can have at least one contact element 88.Without being bound by theory, it is believed that when the tampon 10 isin use the contact element 88 can at least partially expand outwardlyfrom the tampon 10 when contacted by bodily fluids. It is believed thatsuch expansion of the contact element 88 can reduce or prevent leakageof bodily fluids from the woman's vagina.

In an embodiment, a tampon 10 can have at least one contact element 88located at the insertion end 18 of the tampon 10. In an embodiment, atampon 10 can have at least one contact element 88 located at thewithdrawal end 20 of the tampon. In an embodiment, a tampon 10 can haveat least one contact element 88 located at both the insertion end 18 andthe withdrawal end 20 of the tampon 10. In an embodiment, a tampon 10can have at least one contact element 88 at a location of the tampon 10between the insertion end 18 and the withdrawal end 20. In anembodiment, a tampon 10 can have at least one contact element 88 at alocation of the tampon 10 between the insertion end 18 and thewithdrawal end 20 and at least one contact element 88 located at atleast one of the insertion end 18 and/or the withdrawal end 20 of thetampon 10.

In an embodiment, a contact element 88 can at least partially expandoutwardly from the tampon 10 when contacted by body fluids. Withoutbeing bound by theory, it is believed that, while the entire tampon 10may expand from a compressed configuration into a less compressedconfiguration when contacted by body fluids, when a contact element 88is contacted by body fluids and at least partially expands away from thetampon 10 as a result of such contact, the expansion of a contactelement 88 away from the tampon 10 can result in an expanded contactelement 88 region having a cross-sectional diameter that is greater thana cross-sectional diameter of the remaining expanded tampon 10. FIG. 1provides a non-limiting illustration of a compressed tampon 10 of thecurrent disclosure. As illustrated in FIG. 1, the tampon 10 can have atleast one contact element 88 located at the insertion end 18 of thetampon 10. FIG. 10 provides a non-limiting example of an activatedtampon 10, i.e., an expanded tampon 10, wherein the contact elements 88can expand away from the tampon 10 and the region of the contactelements 88 can have a greater cross-sectional diameter than theremainder of the tampon 10. As a contact element 88 expands outwardlyfrom the tampon 10, the contact element 88 can deform and follow thefolds and convolutions of the walls of the vaginal cavity in order torespond locally to the changes in the vaginal environment.

A contact element 88 can have a base 92. In an embodiment, a base 92 ofat least one contact element 88 can be located at the insertion end 18of a tampon 10. In an embodiment, a base 92 of at least one contactelement 88 can be located at the withdrawal end 20 of a tampon 10. In anembodiment, a base 92 of at least one contact element 88 can be locatedat the insertion end 18 of a tampon 10 and a base 92 of at least onecontact element 88 can be located at the withdrawal end 20 of a tampon10. In an embodiment, a base 92 of at least one contact element 88 canbe at a location between the insertion end 18 and the withdrawal end 20of a tampon 10. In an embodiment, a base 92 of at least one contactelement 88 can be at a location between the insertion end 18 and thewithdrawal end 20 of a tampon 10 and a base 92 of a contact element 88can be located at at least one of the insertion end 18 and/or thewithdrawal end 20 of a tampon 10.

In an embodiment, a contact element 88 can be at least partially boundedby a free edge 94 and at least partially bounded by a base 92. In anembodiment, a portion of a free edge 94 of a contact element 88 can atleast partially align with the insertion end 18 of a tampon 10. In anembodiment, a portion of a free edge 94 of a contact element 88 can atleast partially align with the withdrawal end 20 of a tampon 10. In anembodiment, substantially all of the contact element 88 can be locatedbetween the insertion end 18 and the withdrawal end 20 of a tampon 10.In an embodiment, a portion of a free edge 94 of a contact element 88can be at least partially aligned with the insertion end 18 of a tampon10 and a portion of a free edge 94 of a contact element 88 can be atleast partially aligned with the withdrawal end 20 of a tampon 10. In anembodiment, substantially all of a contact element 88 can be locatedbetween the insertion end 18 and the withdrawal end 20 and a portion ofa free edge 94 of a contact element 88 can be at least partially alignedwith at least one of the insertion end 18 and/or the withdrawal end 20of a tampon 10.

In an embodiment, at least one contact element 88 can be orientedtowards the insertion end 18 of the tampon 10. In an embodiment, atleast one contact element 88 can be oriented towards the withdrawal end20 of the tampon 10. In an embodiment, at least one contact element 88can be oriented towards the insertion end 18 of the tampon 10 and atleast one contact element 88 can be oriented towards the withdrawal end20 of the tampon 10.

In an embodiment, each layer, such as layer 36 and 38, can have at leastone contact element 88 located at the insertion end 18, the withdrawalend 20, or at a location between the insertion end 18 and the withdrawalend 20 of a tampon 10. In such an embodiment, a contact element 88 of alayer, such as layer 36, can be, but does not have to be, located in thesame location (i.e., insertion end 18, withdrawal end 20, or a locationbetween the insertion end 18 and the withdrawal end 20) as a contactelement 88 of another layer, such as layer 38. In an embodiment, eachlayer, such as layer 36 and 38, can have at least one contact element 88located at the insertion end 18 of a tampon 10. In an embodiment, eachlayer, such as layer 36 and 38, can have at least one contact element 88located at the withdrawal end 20 of a tampon 10. In an embodiment, oneof the layers, such as layer 36 or 38, can have at least one contactelement 88 located at the insertion end 18 of a tampon 10 and anotherlayer, such as layer 36 or 38, can have at least one contact element 88located at the withdrawal end 20 of the tampon 10. In an embodiment,each of the layers, such as layers 36 and 38, can each have at least onecontact element 88 located at each of the insertion end 18 and thewithdrawal end 20 of a tampon 10. In an embodiment, one of the layers,such as layer 36 or 38, can have a contact element 88 located at atleast one of the insertion end 18 and/or the withdrawal end 20 andanother layer, such as layer 36 or 38, can have a contact element 88located at a location between the insertion end 18 and the withdrawalend 20 of a tampon 10.

In an embodiment in which each of the layers, such as layers 36 and 38,have at least one contact element 88, the at least one contact element88 of each layer, such as layers 36 and 38, can be in any overlappingrelationship to each other as desired. In an embodiment, a contactelement 88 of layer 36 can substantially overlap a contact element 88 oflayer 38. In an embodiment, a contact element 88 of layer 36 canpartially overlap a contact element 88 of layer 38. In an embodiment, acontact element 88 of layer 36 can have minimal or no overlap with acontact element 88 of layer 38.

In an embodiment, at least one of the layer(s), such as layer(s) 36and/or 38, can have at least one contact element 88. In an embodiment,at least one of the layer(s), such as layer(s) 36 and/or 38, can have atleast 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 contact elements 88. In anembodiment, at least one of the layer(s), such as layer(s) 36 and/or 38,can have from 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 to 11, 12, 13, 14, 15,16, 17, 18, 19, or 20 contact elements 88. In an embodiment, each of thelayers, such as layers 36 and 38, can each have at least one contactelement 88. In an embodiment, each of the layers, such as layers 36 and38, can have at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 contact elements88. In an embodiment, each of the layers, such as layers 36 and 38, canhave from 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 to 11, 12, 13, 14, 15, 16,17, 18, 19, or 20 contact elements 88.

In an embodiment, at least one layer(s), such as layer(s) 36 and/or 38,can have at least one contact element 88 at least partially separatedfrom another contact element 88. In an embodiment, the partialseparation of one contact element 88 from another contact element 88 canoccur via an amplitude of an arc, a slit, or combination thereof.

FIGS. 11-24 illustrate various non-limiting examples of embodiments ofan absorbent structure 34 in which at least one layer, such as layer 36and/or 38, can have at least one contact element 88. It is to beunderstood that the configurations of absorbent structures 34 andcontact elements 88 described and illustrated herein are non-limitingand additional configurations are contemplated by this disclosure.

In an embodiment, a layer(s), such as layer 36 and/or 38, of anabsorbent structure 34 can have a transverse edge which can have anundulating arcuate pattern. In such an embodiment, the undulatingarcuate pattern can produce at least one contact element 88. Theamplitude of each arc can be any amplitude as deemed suitable. In suchan embodiment, a contact element 88 can be at least partially separatedfrom another contact element 88 by the amplitude of the arc. FIG. 11illustrates a non-limiting example of an absorbent structure 34 whichcan have two layers, 36 and 38. As illustrated in FIG. 11, layer 36 canhave a first width 46 which can be substantially the same as the secondwidth 62 of layer 38. As illustrated in FIG. 11, layer 36 can have afirst length 44 which can be longer than a second length 60 of layer 38.Layer 36 can have two transverse edges, 48 and 50, in which transverseedge 48 can have an undulating arcuate pattern. Such an undulatingarcuate pattern can produce contact elements 88 which can be at leastpartially separated from each other by the amplitude of an arc betweeneach contact element 88. In an embodiment, a transverse edge having anarcuate pattern can be located at the insertion end 18 of a resultanttampon 10. In an embodiment, a transverse edge having an arcuate patterncan be located at the withdrawal end 20 of a resultant tampon 10. In anembodiment, a transverse edge having an arcuate pattern can be locatedat a location between the insertion end 18 and the withdrawal end 20 ofa resultant tampon 10. In an embodiment, transverse edges having anarcuate pattern can be located at both the insertion end 18 and thewithdrawal end 20 of a resultant tampon 10. In an embodiment, alayer(s), 36 and/or 38, can have a transverse edge having an arcuatepattern at a location between the insertion end 18 and the withdrawalend 20 and a layer(s), 36 and/or 38, can have a transverse edge havingan arcuate pattern at at least one of the insertion end 18 and/or thewithdrawal end 20 of the tampon 10.

In an embodiment, the free edge 94 of a contact element 88 can begenerated via a slit 96. A slit 96 can extend through a layer(s), suchas layer(s) 36 and/or 38, from a first surface and through to a secondsurface of the layer(s), such as layer(s) 36 and/or 38. For example, aslit 96 can be incorporated into layer 36, extending from a firstsurface 56 of layer 36 through to a second surface 58 of layer 36 toform a free edge 94 of a contact element 88. In an embodiment, alayer(s), such as layer(s) 36 and/or 38, can have at least one slit 96.In an embodiment, a layer(s), such as layer(s) 36 and/or 38, can have atleast 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 slits 96. In an embodiment, alayer(s), such as layer(s) 36 and/or 38, can have from about 1, 2, 3, 4,5, 6, 7, 8, 9, or 10 to about 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20slits 96. In an embodiment, a layer(s), such as layer(s) 36 and/or 38,can have the appropriate number of slits 96 to provide the desirednumber of contact elements 88.

In an embodiment, a slit 96 can be linear, arcuate, any other shape, orcombination thereof. In an embodiment, a slit 96 can have any length 98as desired. The length 98 can be measured as the distance between theterminal ends of the slit 96. In an embodiment in which the slit 96contains an arc, the arc length can be determined by any manner deemedsuitable by one of ordinary skill in order to determine the length 98 ofthe slit 96. In an embodiment, the length 98 of a slit 96 can range fromabout 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 or 15 mm to about16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29 or 30 mm. In anembodiment, the length 98 of a slit 96 can be greater than about 1, 2,3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 or 15 mm. In an embodiment, thelength 98 of a slit 96 can be less than about 30, 29, 28, 27, 26, 25,24, 23, 22, 21, 20, 19, 18, 17, 16, or 15 mm.

In an embodiment in which a layer, such as layer 36 or 38, has more thanone slit 96, each slit 96 can have the same length 98. In an embodimentin which a layer, such as layer 36 or 38, has more than one slit 96, aslit 96 can have a length 98 that differs from the length 98 of at leastone other slit 96. In an embodiment, at least about 20, 25, 40, 45, 50,55, 70, 75, 80 or 85% of the slits 96 in a layer, such as layer 36 or38, can have substantially the same length 98. In an embodiment, about25, 50, or 75% of the slits in a layer, such as layer 36 or 38, can havesubstantially the same length, such as a first slit length, and about25, 50, or 75% of the slits in the same layer, such as layer 36 or 38,can have substantially the same length, such as a second slit length,and the second slit length can be different from the first slit length.In an embodiment in which the slits 96 incorporated into a layer, suchas layer 36 or 38, have varying slit lengths, the slits 96 can beincorporated into the layer, such as layer 36 or 38, in any pattern ofslit lengths as desired.

In an embodiment, an absorbent structure 34 can have two layers, such aslayers 36 and 38, in which each layer, such as layers 36 and 38, canhave more than one slit 96. In an embodiment, each slit 96 in theabsorbent structure 34 can have the same length 98. In an embodiment,the absorbent structure 34 can have a slit 96 that can have a length 98that differs from the length 98 of at least one other slit 96 locatedwithin the absorbent structure 34. In an embodiment, at least about 20,25, 40, 45, 50, 55, 70, 75, 80 or 85% of the slits 96 in the absorbentstructure 34 can have substantially the same length 98. In anembodiment, about 25, 50, or 75% of the slits 96 in the absorbentstructure 34 can have substantially the same length, such as a firstslit length, and about 25, 50, or 75% of the slits 96 in the absorbentstructure 34 can have substantially the same length, such as a secondslit length, and the second slit length can be different from the firstslit length. In an embodiment in which the slits 96 incorporated intothe absorbent structure 34 have varying slit lengths, the slits 96 canbe incorporated into the absorbent structure 34 in any pattern of slitlengths as desired.

In an embodiment, a slit 96 can be incorporated into at least onelayer(s), such as layer(s) 36 and/or 38, when the layer(s), such aslayer(s) 36 and/or 38, is in a flat, unfolded configuration or when thelayer(s), such as layer(s) 36 and/or 38, has a folded configuration. Inan embodiment, a slit 96 can be a continuous or intermittent cut. In anembodiment, a slit 96 can be a line of weakness.

In an embodiment, a slit 96 can be incorporated into a layer(s), such aslayer(s) 36 and/or 38, in any location of the layer(s), such as layer(s)36 and/or 38, as deemed suitable. For example, a slit 96 can beincorporated into a layer(s), such as layer(s) 36 and/or 38, between thetransverse edges of the layer(s), such as layer(s) 36 and/or 38, inassociation with a transverse edge of the layer(s), such as layer(s) 36and/or 38, and combinations thereof.

In an embodiment, a slit 96 can be incorporated into at least onelayer(s), such as layer(s) 36 and/or 38, and can be located in anydesired location between the transverse edges of the layer(s), such aslayer(s) 36 and/or 38. In such an embodiment, the slit 96 need not beassociated with transverse edges of the layer(s), such as layer(s) 36and/or 38. In such an embodiment, the slit 96 can be linear, arcuate,any other shape as desired, or combination thereof and can have anylength 98 as desired. In such an embodiment, more than one slit 96 canbe incorporated into the at least one layer(s), such as layer(s) 36and/or 38, and each slit 96 can be separated from any other slit 96 byany distance as deemed suitable. In such an embodiment, the slit 96 cancreate a contact element 88 that can be at least partially bounded by afree edge 94 and at least partially bounded by a base 92.

FIG. 12 provides a non-limiting example of an absorbent structure 34which can have two layers, 36 and 38. The first layer 36 of theabsorbent structure 34 can have a first length 44 which can be greaterthan the second length 60 of the second layer 38. The first width 46 ofthe first layer 36 can be substantially similar to the second width 62of the second layer 38. The first layer 36 can have two transverseedges, 48 and 50, and the second layer 38 can have two transverse edges,64 and 66. In the non-limiting example, transverse edge 66 of the secondlayer 38 can be substantially aligned with transverse edge 50 of thefirst layer 36. In the non-limiting illustration of FIG. 12, first layer36 can have at least one slit 96 located between transverse edges 48 and50 of layer 36. The slits 96 can extend from a first surface 56 of thefirst layer 36 through to a second surface 58 of the first layer 36. Theslits 96 can be in any configuration as desired, such as, for example,an arcuate configuration. It should be realized that the slits 96 canhave any length 98 as desired and can be spaced apart from each otherany distance as desired. As described herein, transverse edge 48 can belocated at the insertion end 18 or the withdrawal end 20 of a resultanttampon 10. In an embodiment, the contact elements 88 of the absorbentstructure 34 illustrated in FIG. 12 can be located at the insertion end18 or the withdrawal end 20 of a resultant tampon 10. In thenon-limiting embodiment illustrated in FIG. 12, the contact elements 88can be oriented towards the insertion end 18 or the withdrawal end 20 ofa resultant tampon 10. In an embodiment, a slit 96 can also beincorporated into second layer 38.

In an embodiment, a slit 96 can be associated with a transverse edge ofa layer, such as, for example, transverse edge 48 of layer 36, and canextend from the transverse edge 48 in a direction towards the interiorregion of the layer, such as, for example, the interior region of layer36. In such an embodiment, the slit 96 can extend from the transverseedge 48 of layer 36 in a direction towards the opposite transverse edge,edge 50, of layer 36. As described herein, in an embodiment, a slit 96need not be associated with a transverse edge of a layer, such astransverse edge 48 of layer 36.

In an embodiment, such as, for example, an embodiment in which more thanone slit 96 can be associated with a transverse edge of a layer, such aslayer 36 or 38, a width 102 (illustrated in FIG. 13) can separate a slit96 from the next successive slit 96. The width 102 can be any distanceas deemed suitable. In an embodiment, the width 102 can range from about1, 2, 3, 4, 5, 6 or 7 mm to about 8, 9, 10, 11, 12, 13, 14 or 15 mm. Inan embodiment in which slits 96 are associated with a transverse edge ofa layer, such as layer 36 or 38, as described herein, the width 102 canbe the width of a contact element 88. Two successive slits 96 associatedwith a transverse edge can create a contact element 88.

FIG. 13-24 illustrate various embodiments of slits 96 incorporated intoat least one layer, 36 and/or 38, of an absorbent structure 34 andassociated with a transverse edge. As shown in the non-limiting examplesof FIG. 13-24, the slits 96 can be incorporated into a layer(s), 36and/or 38, such as, for example, by being cut through from a firstsurface to a second surface of at least one layer, such as layer 36and/or 38. While particular embodiments are illustrated and described,it is to be understood that various changes and modifications can bemade to the embodiments illustrated and described without departing fromthe spirit and scope of the disclosure.

FIG. 13 provides a non-limiting example of an absorbent structure 34which can have two layers, 36 and 38. The first layer 36 of theabsorbent structure 34 can have a first length 44 which can be greaterthan the second length 60 of the second layer 38. The first width 46 ofthe first layer 36 can be substantially similar to the second width 62of the second layer 38. The first layer 36 can have two transverseedges, 48 and 50, and the second layer 38 can have two transverse edges,64 and 66. In the non-limiting example, transverse edge 66 of the secondlayer 38 can be substantially aligned with transverse edge 50 of thefirst layer 36. In the non-limiting illustration of FIG. 13, first layer36 can have at least one slit 96 associated with transverse edge 48. Thefirst layer 36 can have at least two successive slits 96 associated withtransverse edge 48 and the two successive slits 96 can create a contactelement 88. The slits 96 can extend from a first surface 56 of the firstlayer 36 through to a second surface 58 of the first layer 36. The slits96 can extend from the transverse edge 48 in a direction away from thetransverse edge 48 and towards an interior region of the first layer 36of the absorbent structure 34 such that the slits 96 can extend in adirection toward the opposite transverse edge 50 of the first layer 36.It should be realized that the slits 96 can have any length 98 asdesired as the slits 96 extend from transverse edge 48 in a directiontowards the opposite transverse edge 50 of the first layer 36. Asillustrated in FIG. 13 in a non-limiting embodiment, at least one of theslits 96 can have a first slit length 104 and at least one of the slits96 can have a second slit length 106 wherein the first slit length 104and the second slit length 106 are not the same. As illustrated in FIG.13 in the non-limiting embodiment illustrated, the slits 96 may beincorporated into layer 36 in a pattern of alternating lengths. In anembodiment in which slits 96 having different lengths are incorporatedinto a layer, such as layer 36 and/or 38, the slits 96 having differentlengths can be incorporated into the respective layer such that thedifferent lengths of the slits 96 can be in a random sequence, in analternating pattern, or in a repeating pattern. As illustrated in FIG.13, the slits 96 do not necessarily extend the entire first length 44 ofthe first layer 36. While the second layer 38 is illustrated such thattransverse edge 66 can be substantially aligned with transverse edge 50of the first layer 36, it should be realized that transverse edge 66 ofsecond layer 38 does not need to be substantially aligned withtransverse edge 50 of the first layer 36. It should be realized thatsecond layer 38 can be bonded to the first layer 36 at any positionalong the first length 44 of the first layer 36 as deemed suitable. Itshould be realized that transverse edge 64 of second layer 38 can alsobe positioned anywhere along the first length 44 of the first layer 36as desired and the second length 60 of second layer 38 can be anydimension as desired. In an embodiment, layer 38 can at least partiallyor completely overlay the contact elements 88 incorporated into layer36. As described herein, transverse edge 48 can be located at theinsertion end 18 or the withdrawal end 20 of a resultant tampon 10. Inan embodiment, the contact elements 88 of the absorbent structure 34illustrated in FIG. 13 can be located at the insertion end 18 or thewithdrawal end 20 of a resultant tampon 10. In the non-limitingembodiment illustrated in FIG. 13, the contact elements 88 can beoriented towards the insertion end 18 or the withdrawal end 20 of aresultant tampon 10. In an embodiment, a slit 96 can also beincorporated into second layer 38.

FIG. 14 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 in which the first layer 36 canhave a first length 44 greater than the second length 60 of the secondlayer 38. As illustrated in FIG. 14, the first width 46 of the firstlayer 36 can be substantially similar to the second width 62 of thesecond layer 38. In the non-limiting example illustrated in FIG. 14, thesecond layer 38 can be bonded to the first layer 36 in the centralregion of the first length 44 of the first layer 36. The central regionof the first length 44 can be the area adjacent a center line 84 of thefirst length 44 of the first layer 36 of the absorbent structure 34. Itis to be understood that the central region of the first length 44 doesnot need to be the exact center of the first layer 36, but can belocated generally around the center line 84 of the first length 44. Inan embodiment, the central region of the first layer 36 can be aposition along the first length 44 which can be a distance 86 that canbe about 0.35 to about 0.65 times the first length 44, as measured fromeither transverse edge, 48 or 50, of the first layer 36. In anembodiment, the second layer 38 does not have to be bonded to the firstlayer 36 in the central region of the first length 44, but rather couldbe bonded to the first layer 36 in an area adjacent to one of thetransverse edges, 48 or 50, or at any other position along the firstlength 44 of the first layer 36 as deemed suitable. In the non-limitingillustration of FIG. 14, the first layer 36 can have at least one slit96 associated with each of the transverse edges, 48 and 50, of firstlayer 36. The first layer 36 can have at least two successive slits 96associated with transverse edges 48 and 50, respectively, and the twosuccessive slits 96 associated with a transverse edge can create acontact element 88. The slits 96 can extend from a first surface 56 ofthe first layer 36 through to a second surface 58 of the first layer 36.The slits 96 can extend from the transverse edge, 48 or 50,respectively, in a direction towards an interior region of the firstlayer 36 of the absorbent structure 34 such that the slits 96 can extendfrom the associated transverse edge, 48 or 50, and in a direction towardthe opposite transverse edge, 48 or 50, respectively, of the first layer36. It should be realized that the slits 96 can have any length 98 asdesired as the slits 96 extend from a transverse edge, 48 or 50, in adirection towards the opposite transverse edge, 48 or 50, of the firstlayer 36. As illustrated in FIG. 14 in a non-limiting embodiment, atleast one of the slits 96 can have a first slit length 104 and at leastone of the slits 96 can have a second slit length 106 wherein the firstslit length 104 and the second slit length 106 are not the same. Asillustrated in FIG. 14 in a non-limiting embodiment, the slits 96 may beincorporated into layer 36 in a pattern of alternating lengths. In anembodiment in which slits 96 having different lengths are incorporatedinto a layer, such as layer 36 and/or 38, the slits 96 having differentlengths can be incorporated into the respective layer such that thedifferent lengths of the slits 96 can be in a random sequence, in analternating pattern, or in a repeating pattern. As illustrated in FIG.14, the slits 96 do not necessarily extend the entire first length 44 ofthe first layer 36. It should be realized that transverse edges, 64 and66, of second layer 38 can be positioned anywhere along the first length44 of the first layer 36 as desired and the second length 60 of secondlayer 38 can be any dimension as desired. In an embodiment, layer 38 canat least partially or completely overlay the contact elements 88incorporated into layer 36. As described herein, the transverse edges,48 and 50, can be located at the insertion end 18 and the withdrawal end20 of a resultant tampon 10. Thus, in an embodiment, the contactelements 88 of the absorbent structure 34 illustrated in FIG. 14 can belocated at the insertion end 18 and the withdrawal end 20 of a resultanttampon 10. In the non-limiting embodiment illustrated in FIG. 14, thecontact elements 88 can be oriented towards the insertion end 18 and thewithdrawal end 20 of a resultant tampon 10. In an embodiment, a slit 96can also be incorporated into second layer 38.

FIG. 15 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 in which the first layer 36 canhave a first width 46 greater than the second width 62 of the secondlayer 38. As illustrated in FIG. 15, the first length 44 of the firstlayer 36 can be substantially similar to the second length 60 of thesecond layer 38. In the non-limiting example illustrated in FIG. 15, thesecond layer 38 can be bonded to the central region of the first width46 of the first layer 36. The central region of the first width 46 canbe the area adjacent a center line 78 of the first width 46 of the firstlayer 36 of the absorbent structure 34. It is to be understood that thecentral region of the first width 46 does not need to be the exactcenter of the first layer 36, but can be located generally around thecenter line 78 of the first width 46. In an embodiment, the centralregion of the first width 46 of the first layer 36 can be a positionalong the first width 46 which can be a distance 80 that can be about0.35 to about 0.65 times the first width 46, as measured from eitherlongitudinal edge, 52 or 54, of the first layer 36. In an embodiment,the second layer 38 does not have to be bonded to the first layer 36 inthe central region of the first width 46, but rather could be bonded tothe first layer 36 in an area adjacent to one of the longitudinal edges,52 or 54, or at any other position along the first width 46 of the firstlayer 36 as deemed suitable. In the non-limiting embodiment of FIG. 15,first layer 36 can have at least one slit 96 associated with transverseedge 48 and second layer 38 can have at least one slit 96 associatedwith transverse edge 64. Each layer, 36 and 38, can have at least twosuccessive slits 96 associated with their respective transverse edges,48 and 64, and the two successive slits 96 can create a contact element88 in each layer, 36 and 38. With regards to the at least one slit 96associated with the transverse edge 48 of the first layer 36, the slit96 can extend from a first surface 56 of the first layer 36 through to asecond surface 58 of the first layer 36. The slit 96 associated withtransverse edge 48 can extend from the transverse edge 48 in a directiontowards an interior region of the first layer 36 of the absorbentstructure 34 such that the slit 96 can extend in a direction towards theopposite transverse edge 50 of the first layer 36. With regards to theat least one slit 96 associated with the transverse edge 64 of thesecond layer 38, the slit 96 can extend from a first surface 72 throughto a second surface 74 of the second layer 38. The slit 96 associatedwith transverse edge 64 can extend from the transverse edge 64 in adirection towards an interior region of the second layer 38 of theabsorbent structure 34 such that the slit 96 can extend from thetransverse edge 64 in a direction towards the opposite transverse edge66 of the second layer 38. While the slits 96 of the first layer 36 andthe slits 96 of the second layer 38 are illustrated in a manner in whichthe slits 96 of the second layer 38 can be positioned to substantiallyalign with the slits 96 of the first layer 36, it should be realizedthat the slits 96 of the second layer 38 can be offset from the slits 96of the first layer 36. An offset of the slits 96 of the second layer 38from the slits 96 of the first layer 36 can be in any amount as deemedsuitable. It should be realized that the slits 96 of each of the layers,36 and 38, can have any length 98 as desired as the slits 96 extend froma transverse edge, 48 or 64, in a direction towards the oppositetransverse edge, 50 or 66, of the first layer 36 or second layer 38,respectively. As illustrated in FIG. 15 in a non-limiting embodiment, atleast one of the slits 96 of layer 36 and/or 38 can have a first slitlength 104 and at least one of the slits 96 of the same layer, 36 and/or38, can have a second slit length 106 wherein the first slit length 104and the second slit length 106 are not the same. As illustrated in FIG.15 in a non-limiting embodiment, the slits 96 may be incorporated intolayer 36 and layer 38 in a pattern of alternating lengths. In anembodiment in which slits 96 having different lengths are incorporatedinto a layer, such as layer 36 and/or 38, the slits 96 having differentlengths can be incorporated into the respective layer such that thedifferent lengths of the slits 96 can be in a random sequence, in analternating pattern, or in a repeating pattern. As illustrated in FIG.15, the slits 96 do not necessarily extend the entire length, 44 or 60,of the first layer 36 or the second layer 38, respectively. As describedherein, the transverse edges, 48, 50, 64, and 66, can be located at theinsertion end 18 or the withdrawal end 20 of a resultant tampon 10.Thus, in an embodiment, the contact elements 88 of the absorbentstructure 34 illustrated in FIG. 15 can be located at the insertion end18 or the withdrawal end 20 of a resultant tampon 10. In thenon-limiting embodiment illustrated in FIG. 15, the contact elements 88of layers 36 and 38 can be oriented towards the insertion end 18 or thewithdrawal end 20 of a resultant tampon 10. In an embodiment, at leastone of the layers, 36 and/or 38, can also have at least one slit 96associated with the opposite transverse edge, 50 and/or 66,respectively. It should be realized that in the non-limiting embodimentillustrated in FIG. 15, the contact elements 88 of the first layer 36and the contact elements 88 of the second layer 38 need not be bonded toeach other. Thus, it should be realized that the two layers, 36 and 38,do not need to be bonded to each other in any region wherein a contactelement 88 is present.

FIG. 16 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 in which the first layer 36 canhave a first length 44 and a first width 46 that can each be greaterthan the second length 60 and the second width 62 of the second layer38. In the non-limiting illustration of FIG. 16, first layer 36 can haveat least one slit 96 associated with a transverse edge such astransverse edge 48. The first layer 36 can have at least two successiveslits 96 associated with transverse edge 48 and the two successive slits96 can create a contact element 88. The slits 96 can extend from a firstsurface 56 of the first layer 36 through to a second surface 58 of thefirst layer 36. The slits 96 can extend from the transverse edge 48 in adirection away from the transverse edge 48 and towards an interiorregion of the first layer 36 of the absorbent structure 34 such that theslits 96 can extend in a direction toward the opposite transverse edge50 of the first layer 36. It should be realized that the slits 96 canhave any length 98 as desired as the slits 96 extend from transverseedge 48 in a direction towards the opposite transverse edge 50 of thefirst layer 36. As illustrated in FIG. 16 in a non-limiting embodiment,each slit 96 can have a length 98 substantially similar to the length 98of each other slit 96 present. In an embodiment, the slits 96 can havevarying lengths 98. As illustrated in FIG. 16, the slits 96 do notnecessarily extend the entire first length 44 of the first layer 36. Inan embodiment, the slits 96 can extend a length 98 that is substantiallysimilar to, less than or greater than a distance 118 between transverseedge 48 and transverse edge 64. It should be realized that second layer38 can be bonded to the first layer 36 at any position along the firstlength 44 and/or first width 46 of the first layer 36 as deemed suitableand can have any size dimension as deemed suitable. It should berealized that the two layers, 36 and 38, do not need to be bonded toeach other in any region wherein a contact element 88 is present. Asdescribed herein, the transverse edge 48 can be located at the insertionend 18 or the withdrawal end 20 of a resultant tampon 10. Thus, in anembodiment, the contact elements 88 of the absorbent structure 34illustrated in FIG. 16 can be located at the insertion end 18 or thewithdrawal end 20 of a resultant tampon 10. In the non-limitingembodiment illustrated in FIG. 16, the contact elements 88 can beoriented towards the insertion end 18 or the withdrawal end 20 of aresultant tampon 10. In embodiment, at least one slit 96 can also beincorporated into second layer 38.

FIG. 17 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 which can have two layers, 36and 38. As illustrated, first layer 36 can have a first width 46 thatcan be substantially similar to a second width 62 of the second layer38. As illustrated, first layer 36 can have at least one fold 110incorporated therein. In such an embodiment in which a fold 110 ispresent, the first layer 36 can be bent upon itself such that a firstportion of at least one of the surfaces, 56 or 58, can be incommunication with a second portion of the same surface, 56 or 58. As anon-limiting example, as illustrated in FIG. 17, the first layer 36 cancontain a single fold 110 bringing a first portion 112 of the firstsurface 56 into communication with a second portion 114 of the firstsurface 56. In the non-limiting embodiment illustrated in FIG. 17, thefold 110 can bring transverse edge 48 of first layer 36 intocommunication with transverse edge 64 of the second layer 38. It shouldbe realized that layer 36 can have a first length 44 greater than asecond length 60 of layer 38 and fold 110 can occur at any desiredlocation along the first length 44 of layer 36. In an embodiment, a fold110 can bring transverse edge 48 of layer 36 into communication withtransverse edge 64 of layer 38, into communication with a portion ofsecond layer 38 located between transverse edges 64 and 66, intocommunication with transverse edge 66 of second layer 38, into aconfiguration wherein transverse edge 48 can extend beyond transverseedge 66, or to a location of first layer 36 such that transverse edge 48is not in communication with the second layer 38. As illustrated, firstlayer 36 can have at least one slit 96 which can be cut through from asecond surface 58, through the first and second portions, 112 and 114,of the first surface 56, and to the opposite second surface 58 of thefirst layer 36. The first layer 36 can have at least two successiveslits 96 and the two successive slits 96 can create a contact element88. As illustrated, the slit(s) 96 can be associated with the fold 110of the first layer 36. The slit(s) 96 can extend from the fold 110 ofthe first layer 36 in a direction away from the fold 110 and towards theinterior region of the absorbent structure 34 such that the slits 96 canextend from the fold 110 of first layer 36 in a direction towardstransverse edge 50 of layer 36. The slit(s) 96 can be incorporated intothe first layer 36 prior to or after fold 110 has been incorporated intolayer 36. It should be realized that, in an embodiment, at least oneslit 96 can be incorporated into second layer 38. In an embodiment, atleast one of the layers, 36 and/or 38, can have at least one slit 96associated with the transverse edges, 48, 50, 64 and/or 66,respectively. As described herein, the fold 110 can be located at theinsertion end 18 or the withdrawal end 20 of a resultant tampon 10.Thus, in an embodiment, the contact elements 88 of the absorbentstructure 34 illustrated in FIG. 17 can be located at the insertion end18 or the withdrawal end 20 of a resultant tampon 10. In thenon-limiting embodiment illustrated in FIG. 17, the contact elements 88can be oriented towards the insertion end 18 or the withdrawal end 20 ofa resultant tampon 10.

FIG. 18 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 which can have two layers 36 and38. As illustrated, the first layer 36 can have two transverse edges, 48and 50, and the second layer 38 can have two transverse edges, 64 and66. In an embodiment, the first layer 36 can have more than one fold,such as folds 110 and 122, incorporated therein. In such an embodiment,the first fold 110 can bring transverse edge 48 of first layer 36 intocommunication with transverse edge 64 of the second layer 38. In anembodiment, fold 110 can bring transverse edge 48 of layer 36 intocommunication with transverse edge 64 of layer 38, into communicationwith a portion of layer 38 located between transverse edges 64 and 66,into communication with transverse edge 66 of layer 38, into aconfiguration wherein transverse edge 48 can extend beyond transverseedge 66, or to a location of layer 36 such that transverse edge 48 isnot in communication with layer 38. In such an embodiment, a firstportion 112 of first surface 56 of the first layer 36 can be broughtinto a face-to-face relationship with a second portion 114 of firstsurface 56 of the first layer 36. In an embodiment, the fold 110 can beutilized to bring the two portions, 112 and 114, into a facingrelationship and, in some embodiments, a space 120 can exist between thetwo portions, 112 and 114, while they are in a facing relationship. Inan embodiment, such as illustrated in the non-limiting embodiment ofFIG. 18, a second fold 122 can be incorporated into layer 36. In thenon-limiting illustration, the second fold 122 can be incorporated intolayer 36 at any location of the first layer 36 such as, for example, ata location between the transverse edge 48 and the first fold 110. Thesecond fold 122 can be configured such that the second fold 122 canposition a portion of the first layer 36 into the space 120 created bythe first fold 110. The second fold 122 can bring a first portion 124 ofthe second surface 58 into a facing relationship with a second portion126 of the second surface 58 of the first layer 36. The first layer 36can have at least one slit 96 incorporated therein (not shown). The atleast one slit 96 can be incorporated into layer 36 before or after theincorporation of either of the folds, 110 and/or 122. The at least oneslit 96 can be associated with either or both of the folds 110 and/or122. In an embodiment in which slits 96 are associated with only one ofthe folds, 110 or 122, the contact element(s) 88 formed by theincorporation of the slits 96 can be in an at least partiallyoverlapping relationship with a portion of the folded first layer 36 notcontaining any slits 96 or contact elements 88. In an embodiment inwhich slits 96 are associated with each of the folds, 110 and 122, thecontact element(s) 88 formed by the incorporation of the slits 96 can bein an at least partially overlapping relationship. As described herein,the folds 110 and 122 can be located at the insertion end 18 or thewithdrawal end 20 of a resultant tampon 10. Thus, in an embodiment, thecontact elements 88 of the absorbent structure 34 illustrated in FIG. 18can be located at the insertion end 18 or the withdrawal end 20 of aresultant tampon 10. In the non-limiting embodiment illustrated in FIG.18, the contact elements 88 can be oriented towards the insertion end 18or the withdrawal end 20 of a resultant tampon 10. In an embodiment, atleast one slit 96 can be incorporated into second layer 38. In anembodiment, at least one of the layers, 36 and/or 38, can have at leastone slit 96 associated with the transverse edges, 48, 50, 64 and/or 66,respectively.

FIG. 19 provides an illustration of a non-limiting embodiment of anabsorbent structure 34 which can have two layers, 36 and 38. Asillustrated, the first layer 36 can have a first width 46 that can besubstantially similar to a second width 62 of the second layer 38. Thefirst layer 36 can have a first length 44 which can be longer than asecond length 60 of the second layer 38. As illustrated, first layer 36can have at least two folds, 110 and 122, incorporated therein. In suchan embodiment in which two folds, 110 and 122, are present, the layer 36can be bent upon itself such that a first portion of one surface, 56 or58, of the layer 36 can be in a facing relationship with a secondportion of the same surface, 56 or 58, and a third portion of onesurface, 56 or 58, of the layer 36 can be in a facing relationship witha first portion of the other surface, 56 or 58. As a non-limitingexample, as illustrated in FIG. 19, the layer 36 can contain a firstfold 110 bringing a first portion 112 of the first surface 56 into afacing relationship with a second portion 114 of the first surface 56.Following the creation of the first fold 110, the transverse edge 48 oflayer 36 can be located at any location along the first length 44 oflayer 36 between the first fold 110 and transverse edge 64 of layer 38.The layer 36 can contain a second fold 122 bringing a third portion 128of the first surface 56 into a facing relationship with a first portion124 of the second surface 58 of layer 36. The second fold 122 can becreated by bending layer 36 at a location along the first length 44 oflayer 36 between the transverse edge 48 of layer 36 and the transverseedge 64 of layer 38. As illustrated in FIG. 19, following the folding oflayer 36 with fold 122, transverse edge 48 need not be in communicationwith second layer 38 of the absorbent structure 34. In an embodiment,each fold 110 and 122 can result in layer 36 having multiple layers,such as layers 130, 132, and 134. In an embodiment, layer 36 can have atleast one slit 96 extending through the layers, 130, 132 and 134, of thelayer 36. The first layer 36 can have at least two successive slits 96and the two successive slits 96 can create a contact element 88. Asillustrated, the at least one slit 96 can extend from the second surface58 of layer 36, through the first and second portions, 112 and 114, ofthe first surface 56 of layer 36, through the first portion 124 of thesecond surface 58 of layer 36 and the third portion 128 of the firstsurface 56 of layer 36, and to the opposite second surface 58 of thefirst layer 36. As illustrated, the slit(s) 96 can be associated withthe second fold 122 of the first layer 36. The slit(s) 96 can extendfrom the fold 122 of the first layer 36 in a direction away from thefold 122 and towards the interior region of the absorbent structure 34such that the slits 96 can extend from the fold 122 of first layer 36 ina direction towards transverse edge 50 of layer 36. The at least oneslit 96 can be incorporated into layer 36 prior to or after layer 36 hasbeen folded. As described herein, the fold 122 can be located at theinsertion end 18 or the withdrawal end 20 of a resultant tampon 10.Thus, in an embodiment, the contact elements 88 of the absorbentstructure 34 illustrated in FIG. 19 can be located at the insertion end18 or the withdrawal end 20 of a resultant tampon 10. In thenon-limiting embodiment illustrated in FIG. 19, the contact elements 88can be oriented towards the insertion end 18 or the withdrawal end 20 ofa resultant tampon 10. In an embodiment, at least one slit 96 can beincorporated into second layer 38. In an embodiment, at least one of thelayers, 36 and/or 38, can have at least one slit 96 associated with thetransverse edges, 48, 50, 64 and/or 66, respectively.

FIG. 20 provides an illustration of a non-limiting embodiment of anabsorbent structure 34 which can have two layers, 36 and 38. Asillustrated, the first layer 36 can have a first width 46 that can besubstantially similar to a second width 62 of the second layer 38. Thefirst layer 36 can have a first length 44 which can be longer than asecond length 60 of the second layer 38. As illustrated, first layer 36can have at least two folds, 110 and 122, incorporated therein. In suchan embodiment in which two folds, 110 and 122, are present, the layer 36can be bent upon itself such that a first portion of one surface, 56 or58, of the layer 36 can be in a facing relationship with a secondportion of the same surface, 56 or 58, and a third portion of onesurface, 56 or 58, of the layer 36 can be in a facing relationship witha first portion of the other surface, 56 or 58. As a non-limitingexample, as illustrated in FIG. 20, the layer 36 can contain a firstfold 110 bringing a first portion 112 of the first surface 56 into afacing relationship with a second portion 114 of the first surface 56.Following the creation of the first fold 110, the transverse edge 48 oflayer 36 can be located at any location along the first length 44 oflayer 36 between the first fold 110 and transverse edge 64 of layer 38.The layer 36 can contain a second fold 122 bringing a third portion 128of the first surface 56 into a facing relationship with a first portion124 of the second surface 58 of layer 36. The second fold 122 can becreated by bending layer 36 at a location along the first length 44 oflayer 36 between the transverse edge 48 of layer 36 and the transverseedge 64 of layer 38. As illustrated in FIG. 20, following the folding oflayer 36 with fold 122, transverse edge 48 need not be in communicationwith second layer 38 of the absorbent structure 34. In an embodiment,each fold 110 and 122 can result in layer 36 having multiple layers,such as layers 130, 132, and 134. In an embodiment, layer 36 can have atleast one slit 96 extending through the layers, 130 and 132, of thelayer 36. The first layer 36 can have at least two successive slits 96extending through the layers, 130 and 132, and the two successive slits96 can create a contact element 88. As illustrated, the at least oneslit 96 can extend from the second surface 58 of layer 36 and throughthe first and second portions, 112 and 114, of the first surface 56 oflayer 36 to the first portion 124 of the second surface 58 of layer 36.As illustrated, the slit(s) 96 can be associated with the first fold 110of the first layer 36. The slit(s) 96 can extend from the fold 110 ofthe first layer 36 in a direction away from the fold 110 and towards thesecond fold 122 of the first layer 36. The at least one slit 96 can beincorporated into layer 36 prior to or after layer 36 has been foldedwith the first fold 110. As described herein, the fold 110 can belocated at a location between the insertion end 18 and the withdrawalend 20 of a resultant tampon 10. Thus, in an embodiment, the contactelements 88 of the absorbent structure 34 illustrated in FIG. 20 can belocated at a location between the insertion end 18 and the withdrawalend 20 of a resultant tampon 10. In the non-limiting embodimentillustrated in FIG. 20, the contact elements 88 can be oriented towardsthe insertion end 18 or the withdrawal end 20 of a resultant tampon 10.In an embodiment, at least one slit 96 can be incorporated into secondlayer 38. In an embodiment, at least one of the layers, 36 and/or 38,can have at least one slit 96 associated with the transverse edges, 48,50, 64 and/or 66, respectively.

FIG. 21 provides an illustration of a non-limiting embodiment of anabsorbent structure 34 which can have two layers, 36 and 38. Asillustrated, the first layer 36 can have a first width 46 that can besubstantially similar to a second width 62 of the second layer 38. Thefirst layer 36 can have a first length 44 which can be longer than asecond length 60 of the second layer 38. As illustrated, less than 100%of surface 74 of second layer 38 can be in a face to face relationshipwith surface 56 of first layer 36. As illustrated, first layer 36 canhave at least two folds, 110 and 122, incorporated therein. In such anembodiment in which two folds 110 and 122 are present, the layer 36 canbe bent upon itself such that a first portion of one surface, 56 or 58,of the layer 36 can be in a facing relationship with a second portion ofthe same surface, 56 or 58, and a third portion of one surface, 56 or58, of the layer 36 can be in a facing relationship with a first portionof the other surface, 56 or 58. As a non-limiting example, asillustrated in FIG. 21, the layer 36 can contain a first fold 110bringing a first portion 112 of the first surface 56 into a facingrelationship with a second portion 114 of the first surface 56.Following the creation of the first fold 110, the transverse edge 48 oflayer 36 can be located at any location along the first length 44 oflayer 36 between the first fold 110 and transverse edge 64 of layer 38.The layer 36 can contain a second fold 122 bringing a third portion 128of the first surface 56 into a facing relationship with a first portion124 of the second surface 58 of layer 36. The second fold 122 can becreated by bending layer 36 at a location along the first length 44 oflayer 36 between the transverse edge 48 of layer 36 and the transverseedge 64 of layer 38. As illustrated in FIG. 21, following the folding oflayer 36 with fold 122, transverse edge 48 need not be in communicationwith second layer 38 of the absorbent structure 34. In an embodiment,each fold 110 and 122 can result in layer 36 having multiple layers,such as layers 130, 132, and 134. In an embodiment, layer 36 can have atleast one slit 96 extending through the layers, 130 and 132, of thelayer 36. The first layer 36 can have at least two successive slits 96extending through the layers, 130 and 132, and the two successive slits96 can create a contact element 88. As illustrated, the at least oneslit 96 can extend from the second surface 58 of layer 36 and throughthe first and second portions, 112 and 114, of the first surface 56 oflayer 36 to the first portion 124 of the second surface 58 of layer 36.As illustrated, the slit(s) 96 can be associated with the first fold 110of the first layer 36. The slit(s) 96 can extend from the fold 110 ofthe first layer 36 in a direction away from the fold 110 and towards thesecond fold 122 of the first layer 36. The at least one slit 96 can beincorporated into layer 36 prior to or after layer 36 has been foldedwith the first fold 110. As described herein, the fold 110 can belocated at a location between the insertion end 18 and the withdrawalend 20 of a resultant tampon 10. Thus, in an embodiment, the contactelements 88 of the absorbent structure 34 illustrated in FIG. 21 can belocated at a location between the insertion end 18 and the withdrawalend 20 of a resultant tampon 10. In the non-limiting embodimentillustrated in FIG. 21, the contact elements 88 can be oriented towardsthe insertion end 18 or the withdrawal end 20 of a resultant tampon 10.In an embodiment, at least one slit 96 can be incorporated into secondlayer 38. In an embodiment, at least one of the layers, 36 and/or 38,can have at least one slit 96 associated with the transverse edges, 48,50, 64 and/or 66, respectively.

FIG. 22 provides an illustration of a non-limiting embodiment of anabsorbent structure 34 which can have two layers, 36 and 38. Asillustrated, the first layer 36 can have a first width 46 that can besubstantially similar to a second width 62 of the second layer 38. Thefirst layer 36 can have a first length 44 which can be longer than asecond length 60 of the second layer 38. As illustrated, first layer 36can have at least two folds, 110 and 122, incorporated therein. In suchan embodiment as illustrated in FIG. 22 in which two folds, 110 and 122,are present, the layer 36 can be bent upon itself such that a firstportion of one surface, 56 or 58, of the layer 36 can be in a facingrelationship with a second portion of the same surface, 56 or 58, and afirst portion of the other surface, 56 or 58, of the layer 36 can be ina facing relationship with a second portion of the same surface, 56 or58. As a non-limiting example, as illustrated in FIG. 22, the layer 36can contain a first fold 110 bringing a first portion 112 of the firstsurface 56 into a facing relationship with a second portion 114 of thefirst surface 56. Following the creation of the first fold 110, thetransverse edge 48 of layer 36 can be located at any location along thefirst length 44 of layer 36 between the first fold 110 and transverseedge 64 of layer 38. The layer 36 can contain a second fold 122 bringinga first portion 124 of the second surface 58 into a facing relationshipwith a second portion 126 of the second surface 58 of layer 36. Thesecond fold 122 can be created by bending layer 36 at a location alongthe first length 44 of layer 36 between the transverse edge 48 of layer36 and the first fold 110 of layer 36. As illustrated in FIG. 22,transverse edge 48 of layer 36 can be in communication with transverseedge 64 of the second layer 38 of the absorbent structure 34. In anembodiment, each fold 110 and 122 can result in layer 36 having multiplelayers, such as layers 130, 132, 134 and 136. In an embodiment, layer 36can have at least one slit 96 extending through the layers, 130, 132,134 and 136, of the layer 36. The first layer 36 can have at least twosuccessive slits 96 extending through the layers, 130, 132, 134, and136, and the two successive slits 96 can create a contact element 88. Asillustrated, the at least one slit 96 can extend from the second surface58 of layer 36, through the first and second portions, 112 and 114, ofthe first surface 56 of layer 36, through the first and second portions,124 and 126, of the second surface 58 of layer 36, through oppositefirst and second portions, 112 and 114, of the first surface 56 of layer36, and to the opposite second surface 58 of the first layer 36. Asillustrated, the slit(s) 96 can be associated with the second fold 122of the first layer 36. The slit(s) 96 can extend from the fold 122 ofthe first layer 36 in a direction away from the fold 122 and towards theinterior region of the absorbent structure 34 such that the slits 96 canextend from the fold 122 of first layer 36 in a direction towardstransverse edge 50 of layer 36. The at least one slit 96 can beincorporated into layer 36 prior to or after layer 36 has been folded.As described herein, the fold 122 can be located at the insertion end 18or the withdrawal end 20 of a resultant tampon 10. Thus, in anembodiment, the contact elements 88 of the absorbent structure 34illustrated in FIG. 22 can be located at the insertion end 18 or thewithdrawal end 20 of a resultant tampon 10. In the non-limitingembodiment illustrated in FIG. 22, the contact elements 88 can beoriented towards the insertion end 18 or the withdrawal end 20 of aresultant tampon 10. In an embodiment, at least one slit 96 can beincorporated into second layer 38. In an embodiment, at least one of thelayers, 36 and/or 38, can have at least one slit 96 associated with thetransverse edges, 48, 50, 64 and/or 66, respectively.

FIG. 23 provides an illustration of a non-limiting embodiment of anabsorbent structure 34 which can have two layers, 36 and 38. Asillustrated, the first layer 36 can have a first width 46 that can besubstantially similar to a second width 62 of the second layer 38. Thefirst layer 36 can have a first length 44 which can be longer than asecond length 60 of the second layer 38. As illustrated, first layer 36can have at least two folds, 110 and 122, incorporated therein. In suchan embodiment as illustrated in FIG. 23 in which two folds, 110 and 122,are present, the layer 36 can be bent upon itself such that a firstportion of one surface, 56 or 58, of the layer 36 can be in a facingrelationship with a second portion of the same surface, 56 or 58, and afirst portion of the other surface, 56 or 58, of the layer 36 can be ina facing relationship with a second portion of the same surface, 56 or58. As a non-limiting example, as illustrated in FIG. 23, the layer 36can contain a first fold 110 bringing a first portion 112 of the firstsurface 56 into a facing relationship with a second portion 114 of thefirst surface 56. Following the creation of the first fold 110, thetransverse edge 48 of layer 36 can be located at any location along thefirst length 44 of layer 36 between the first fold 110 and transverseedge 64 of layer 38. The layer 36 can contain a second fold 122 bringinga first portion 124 of the second surface 58 into a facing relationshipwith a second portion 126 of the second surface 58 of layer 36. Thesecond fold 122 can be created by bending layer 36 at a location alongthe first length 44 of layer 36 between the transverse edge 48 of layer36 and the first fold 110 of layer 36. As illustrated in FIG. 23,transverse edge 48 of layer 36 can be in communication with transverseedge 64 of the second layer 38 of the absorbent structure 34. In anembodiment, each fold 110 and 122 can result in layer 36 having multiplelayers, such as layers 130, 132, 134 and 136. In an embodiment, layer 36can have at least one slit 96 extending through the layers, such aslayers 130 and 132, of the layer 36. The first layer 36 can have atleast two successive slits 96 extending through the layers, 130 and 132,and the two successive slits 96 can create a contact element 88. Asillustrated, the at least one slit 96 can extend from the second surface58 of layer 36, through the first and second portions, 112 and 114, ofthe first surface 56 of layer 36, and to the second portion 126 of thesecond surface 58 of layer 36. As illustrated, the slit(s) 96 can beassociated with the first fold 110 of the first layer 36. The slit(s) 96can extend from the fold 110 of the first layer 36 in a direction awayfrom the fold 110 and towards the second fold 122 of first layer 36. Theat least one slit 96 can be incorporated into layer 36 prior to or afterlayer 36 has been folded. As described herein, the fold 110 can belocated between the insertion end 18 and the withdrawal end 20 of aresultant tampon 10. Thus, in an embodiment, the contact elements 88 ofthe absorbent structure 34 illustrated in FIG. 23 can be located betweenthe insertion end 18 and the withdrawal end 20 of a resultant tampon 10.In the non-limiting embodiment illustrated in FIG. 23, the contactelements 88 can be oriented towards the insertion end 18 or thewithdrawal end 20 of a resultant tampon 10. In an embodiment, at leastone slit 96 can be incorporated into second layer 38. In an embodiment,at least one of the layers, 36 and/or 38, can have at least one slit 96associated with the transverse edges, 48, 50, 64 and/or 66,respectively.

FIG. 24 provides an illustration of a non-limiting embodiment of anabsorbent structure 34 which can have two layers, 36 and 38. Asillustrated, the first layer 36 can have a first width 46 that can besubstantially similar to a second width 62 of the second layer 38. Thefirst layer 36 can have a first length 44 which can be longer than asecond length 60 of the second layer 38. As illustrated, less than 100%of surface 74 of second layer 38 can be in a face to face relationshipwith surface 56 of first layer 36. As illustrated, first layer 36 canhave at least two folds, 110 and 122, incorporated therein. In such anembodiment as illustrated in FIG. 24 in which two folds 110 and 122 arepresent, the layer 36 can be bent upon itself such that a first portionof one surface, 56 or 58, of the layer 36 can be in a facingrelationship with a second portion of the same surface, 56 or 58, and afirst portion of the other surface, 56 or 58, of the layer 36 can be ina facing relationship with a second portion of the same surface, 56 or58. As a non-limiting example, as illustrated in FIG. 24, the layer 36can contain a first fold 110 bringing a first portion 112 of the firstsurface 56 into a facing relationship with a second portion 114 of thefirst surface 56. Following the creation of the first fold 110, thetransverse edge 48 of layer 36 can be located at any location along thefirst length 44 of layer 36 between the first fold 110 and transverseedge 64 of layer 38. The layer 36 can contain a second fold 122 bringinga first portion 124 of the second surface 58 into a facing relationshipwith a second portion 126 of the second surface 58 of layer 36. Thesecond fold 122 can be created by bending layer 36 at a location alongthe first length 44 of layer 36 between the transverse edge 48 of layer36 and the first fold 110 of layer 36. As illustrated in FIG. 24,transverse edge 48 of layer 36 does not have to be, but can be, incommunication with transverse edge 64 of the second layer 38 of theabsorbent structure 34. In an embodiment, each fold 110 and 122 canresult in layer 36 having multiple layers, such as layers 130, 132, 134and 136. In an embodiment, layer 36 can have at least one slit 96extending through the layers, 130 and 132, of the layer 36. The firstlayer 36 can have two successive slits 96 extending through the layers,130 and 132, and the two successive slits 96 can create a contactelement 88. As illustrated, the at least one slit 96 can extend from thesecond surface 58 of layer 36, through the first and second portions,112 and 114, of the first surface 56 of layer 36, and to the secondportion 126 of the second surface 58 of layer 36. As illustrated, theslit(s) 96 can be associated with the first fold 110 of the first layer36. The slit(s) 96 can extend from the fold 110 of the first layer 36 ina direction away from the fold 110 and towards the second fold 122 offirst layer 36. The at least one slit 96 can be incorporated into layer36 prior to or after layer 36 has been folded. As described herein, thefold 110 can be located between the insertion end 18 and the withdrawalend 20 of a resultant tampon 10. Thus, in an embodiment, the contactelements 88 of the absorbent structure 34 illustrated in FIG. 24 can belocated between the insertion end 18 and the withdrawal end 20 of aresultant tampon 10. In the non-limiting embodiment illustrated in FIG.24, the contact elements 88 can be oriented towards the insertion end 18or the withdrawal end 20 of a resultant tampon 10. In an embodiment, atleast one slit 96 can be incorporated into second layer 38. In anembodiment, at least one of the layers, 36 and/or 38, can have at leastone slit 96 associated with the transverse edges, 48, 50, 64 and/or 66,respectively.

As described herein, the nonwoven ribbon 32 of an absorbent structure 34can be separated into individual units of fleece 30 which can have thesame absorbent structure 34 as was present in the nonwoven ribbon 32.The fleece 30 can be formed into a blank 28 which can then be compressedinto a pledget 12 of a tampon 10. In various embodiments, the tampon 10can have a cover 138 and a withdrawal aid 14.

In various embodiments a cover 138 can be provided. As used herein, theterm “cover” relates to materials that are in communication with andcover or enclose surfaces of a pledget 12 to prevent the fibrousmaterials of the absorbent structure 34 from directly contacting theinner walls of a woman's vagina and to reduce the ability of portions(e.g., fibers and the like) from becoming separated from the pledget 12or the tampon 10 and being left behind upon removal of the tampon 10from the woman's vagina. In various embodiments, the cover 138 can be afluid-permeable cover 138. By “fluid-permeable” it is meant that bodyfluid is able to pass through the cover 138. The cover 138 can behydrophobic or hydrophilic. By “hydrophilic” it is meant that the cover138 has an affinity for absorbing or tending to combine with water. By“hydrophobic” it is meant that the cover 138 is antagonistic to ortending not to combine with water. The cover 138 can also be treatedwith a surfactant or other material to make it hydrophilic or to make itmore hydrophilic.

The cover 138 can be bonded with: the nonwoven ribbon 32 prior toseparation into individual units of fleece 30, an individual unit offleece 30, a blank 28 which has been formed from a fleece 30, or to thepledget 12 following compression of the blank 28. In an embodiment inwhich the cover 138 is bonded with a pledget 12 following compression ofa blank 28, the cover 138 can be extensible such that the tampon 10 canexpand within the vaginal cavity. In an embodiment in which theabsorbent structure 34 is multi-layered, the cover 138 can be bondedwith at least one layer of the absorbent structure 34 before, after, orwhile the layer of the absorbent structure 34 is bonded to another layerof the absorbent structure 34. The absorbent structure 34 can be in anonwoven ribbon 32 or can be in a fleece 30.

In various embodiments, the cover 138 can be formed from nonwovenmaterials or apertured films. The nonwoven materials can include, butare not limited to, materials such as natural fibers, synthetic fibers,or blends of natural and synthetic fibers. Natural fibers include, butare not limited to, rayon, cotton, wood pulp, flax, and hemp. Syntheticfibers can include, but are not limited to, fibers such as polyester,polyolefin, nylon, polypropylene, polyethylene, polyacrylic, vinylpolyacetate, polyacrylate, cellulose acetate, or bicomponent fibers,such as bicomponent polyethylene and polypropylene fibers. The cover 138can be made by any number of suitable techniques such as, for example,being spunbonded, carded, hydroentangled, thermally bonded, and resinbonded. In an embodiment, the cover 138 can be formed from an aperturedthermoplastic film having either a two-dimensional or athree-dimensional thickness. In an embodiment, the cover 138 can be a 12gsm smooth calendared material made from bicomponent, polyethylenesheath and polyester core, fibers such as Sawabond 4189 available fromSandler AG, Schwarzenbach, Germany. In an embodiment, the cover 138 canbe formed from a single piece of material. In an embodiment, the cover138 can be formed from multiple discrete pieces of material which arebonded together. In an embodiment, the cover 138 can be bleached. In anembodiment, the cover 138 can have a color.

In an embodiment, the cover 138 can be treated with an aqueous solutionto reduce frictional drag, to give the tampon 10 a permanentwettability, to enhance the ease of insertion into and withdrawal from awoman's vagina, and combinations thereof. In an embodiment, the cover138 can be treated either before being rolled or folded up with thefleece 30 into a blank 28 or after the blank 28 has been formed and thecover 138 has been bonded with the blank 28.

In various embodiments, at least a portion of a cover 138 can cover abody facing surface 148, a portion of an interior surface 146, orcombinations thereof of a blank 28. FIG. 25 provides an illustration ofa non-limiting embodiment in which at least a portion of a cover 138 cancover a portion of a body facing surface 148 of a blank 28, such as asoftwind. As illustrated in FIG. 26A, in an embodiment, at least aportion of a cover 138 can cover a portion of an interior surface 146 ofa blank 28 when a fleece 30 is compressed, such as, for example, viaside compression. As illustrated in FIG. 26A, in an embodiment, at leasta portion of the cover 138 can cover a combination of the body facingsurface 148 and the interior surface 146 of a blank 28. The interiorsurface 146 of the blank 28 can result from folding, rolling, orotherwise manipulating the fleece 30 into the blank 28. It is to beunderstood that in an embodiment, the interior surface 146 of thepledget 12 may come into contact with the vaginal walls as the tampon 10can expand when contacted by body fluids. The expansion of the tampon 10can, therefore, cause exposure of the interior surface 146 of thepledget 12 to the vaginal walls and body fluid. As illustrated in FIG.26B, in an embodiment two covers 138 can be in communication with afleece 30 which can be compressed, such as, for example, via sidecompression, into a blank 28. As illustrated in FIG. 26B, in such anembodiment, at least a portion of each of the covers 138 can cover aportion of an interior surface 146 of a blank 28 of a pledget 12. Insuch an embodiment, at least a portion of each of the covers 138 cancover a combination of the body facing surface 148 and the interiorsurface 146 of a blank 28 of a pledget 12. In various embodiments, thecover 138 can extend beyond the withdrawal end 20 of the pledget 12 toform a skirt 150 as illustrated in FIG. 27. It is to be understood that,in an embodiment, the cover 138 can extend beyond the insertion end 18of a pledget 12.

In an embodiment, the cover 138 can have two edges, 152 and 154. Asnoted above, the cover 138 can be bonded to a nonwoven ribbon 32, afleece 30, a blank 28, or a pledget 12. In an embodiment, during thebonding process, at least one of the edges, 152 or 154, of the cover 138can be substantially aligned with one of the transverse edges, such astransverse edges 48 and 50 or 64 or 66. In an embodiment, during thebonding process, the cover 138 can be bonded to the nonwoven ribbon 32,the fleece 30, the blank 28, or the pledget 12 so as to produce a spiralor helical pattern on the resulting pledget 12. In an embodiment, thetwo edges, 152 and 154, can be perpendicular to the longitudinal axis 16of a pledget 12. In an embodiment, the two edges, 152 and 154, can bepositioned in a direction parallel to the longitudinal axis 16 of apledget 12 or at any other angle to the longitudinal axis 16 of apledget 12 such as may occur if the cover 138 is spirally wound aboutthe pledget 12. Thus, while the cover 138 and the edges, 152 and 154,may be discussed herein in an orientation perpendicular to thelongitudinal axis 16 of a pledget 12, one of ordinary skill will be ableto recognize how to provide a cover 138 and edges, 152 and 154, in anorientation parallel with the longitudinal axis 16 of a pledget 12 or inan orientation having any other angle in relation to the longitudinalaxis 16 of a pledget 12.

In an embodiment, the cover 138 can have uniform properties. In anembodiment, the cover 138 can have non-uniform properties. In such anembodiment, the cover 138 can have regions with differing propertieswhich can be coordinated to increase or decrease absorbency and/or levelof expansion of the tampon 10. For example, a region can be morehydrophilic or hydrophobic in comparison to another region of the cover138. In an embodiment, the hydrophilic region of the cover 138 couldsubstantially cover the portion of the tampon 10 that would contact themenses first to increase menses absorption and as a result increaseexpansion of that portion of the tampon 10.

The regions of the cover 138 with differing properties may be producedby various methods. One example of a method is by treating the regionsof the cover 138 with chemical finishes, such as hydrophilic orhydrophobic finishes that make the regions either more hydrophilic ormore hydrophobic, respectively. The regions can also be mechanicallyaltered. Any method known in the art of mechanically altering non-wovensor films can be used. Mechanically altering includes, but is not limitedto, processes such as ring-rolling, corrugating, SELFing, andaperturing.

The composition of the cover 138 can also provide for differingproperties of the cover 138. Different regions of the cover 138 can beproduced from different materials. For example, one region of the cover138 may have a higher concentration of rayon than another section of thecover 138 to make that region more hydrophilic. Materials could beselected for any property desired for a cover 138 known in the art, suchas a selection of a material to provide a region of the cover 138 withgreater extensibility. In an embodiment, the cover 138 may includemultiple discrete pieces that are bonded together to form a single cover138. The discrete pieces can have differing properties such as describedabove. In an embodiment, the discrete pieces of the cover 138 may formthe different regions of the cover 138 such as described above. In suchan embodiment, one discrete piece may form one region and anotherdiscrete piece may form a different region of the cover 138. Thediscrete pieces can be bonded by any method known to one of ordinaryskill in the art, such as sewing, adhesive, thermal bonding, fusionbonding, or combinations thereof.

As illustrated in FIG. 28, in an embodiment, the cover 138 can have atleast one slit 156. In an embodiment, the slit(s) 156 can be locatedbetween the two edges, 152 and 154, of the cover 138. In such anembodiment, the slit 156 can form a cover contact element 162. In anembodiment, the slit(s) 156 can be associated with at least one of theedges, 152 and/or 154. In an embodiment, at least one slit 156 can beassociated with at least one of the edges, 152 and/or 154, and at leastone slit 156 can be located between the two edges, 152 and 154. In anembodiment in which slits 156 are associated with at least one of theedges, 152 and 154, the cover 138 can have at least two slits 156 whichcan form a cover contact element 162. The cover contact element 162 cancome into contact with the walls of the vagina and can direct fluid flowtowards the tampon 10. In an embodiment, the cover 138 can have at leastone cover contact element 162. In an embodiment, the cover 138 can haveat least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 cover contact elements 162. Inan embodiment, the cover 138 can have from about 1, 2, 3, 4, 5, 6, 7, 8,9, or 10 to about 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 cover contactelements 162. In an embodiment, a cover contact element 162 can beoriented perpendicular to the longitudinal axis 16 of a tampon 10. In anembodiment, a cover contact element 162 can be oriented parallel withthe longitudinal axis 16 of a tampon 10. In an embodiment, a covercontact element 162 can be oriented at any angle as desired to thelongitudinal axis 16 of a tampon 10.

In an embodiment, a slit 156 of the cover 138 can be substantiallyaligned with a slit 96 of a layer(s), such as layer(s) 36 and/or 38. Inan embodiment, a slit 156 can be offset from a slit 96 of a layer(s),such as layer(s) 36 and/or 38. In an embodiment, a slit 156 of a cover138 can be substantially aligned with a slit 96 of a layer(s), such aslayer(s) 36 and/or 38, and a slit 156 of a cover 138 can be offset froma slit 96 of a layer(s), such as layer(s) 36 and/or 38. In thenon-limiting embodiment illustrated in FIG. 28, the slits 156 of thecover 138 can be substantially aligned with the slits 96 of a layer ofthe absorbent structure 34. In such an embodiment, a slit 156 in thecover 138 can allow the contact element 88 to expand in a direction awayfrom the tampon 10 and to deform and flex away from the tampon 10. In anembodiment, the length of a slit 156 in the cover 138 can be any lengthdeemed suitable. In an embodiment, the length of a slit 156 in the cover138 can be substantially similar to the length 98 of a slit 96 in alayer(s), such as layer(s) 36 and/or 38. In an embodiment, a widthbetween two successive slits 156 in the cover 138 can be any width asdeemed suitable. In an embodiment, the width between two successiveslits 156 in the cover 138 can be substantially similar to the width 102between two successive slits 96 in one of the layers, 36 and/or 38. Inan embodiment, the length of a slit 156 and the width between twosuccessive slits 156 in the cover 138 can be substantially similar to ordifferent from the length 98 of a slit 96 and the width 102 betweenslits 96 in a layer(s), such as layer(s) 36 and/or 38, when the slits156 in a cover 138 substantially align with the slits 96 in a layer(s),such as layer(s) 36 and/or 38, or when the slits 156 in a cover 138 areoffset from the slits 96 in a layer(s), such as layer(s) 36 and/or 38.In an embodiment, a cover contact element 162 can substantially alignwith a contact element 88 of a layer(s), such as layer(s) 36 and/or 38.In an embodiment, a cover contact element 162 can be offset from acontact element 88 of a layer(s), such as layer(s) 36 and/or 38.

In various embodiments, the pledget 12 may be subject to furtherprocessing to result in a finished tampon. For example, the pledget 12may be joined with a withdrawal aid 14 and/or applicator.

The withdrawal aid 14 may be attached to the pledget 12 in any suitablemanner. For example, an opening can be formed through the pledget 12(and cover 138 if provided) so as to provide a means for attaching awithdrawal aid 14. In various embodiments, the withdrawal aid 14 can beattached to the fibrous material before or after it is compressed intothe pledget 12. The withdrawal aid 14 can be attached to the fibrousmaterial and then looped upon itself. As illustrated in FIG. 29, thewithdrawal aid 14 can be associated with the nonwoven ribbon 32 and canfurther be associated with the fleece 30. In such an embodiment, thewithdrawal aid 14 can be, as illustrated, wound with the fleece 30 inthe formation of a blank 28. A knot 144 can be formed near the free endsof the withdrawal aid 14 to assure that the withdrawal aid 14 does notseparate from the fibrous material. The knot 144 can also serve toprevent fraying of the withdrawal aid 14 and to provide a location wherea woman can grasp the withdrawal aid 14 when she is ready to remove thetampon 10 from her vagina.

The withdrawal aid 14 can be constructed from various types of threadsor ribbons. A thread or ribbon can be made from 100% cotton fibersand/or other materials in whole or part. The withdrawal aid 14 can bebonded to the absorbent fibers with or without tying. The withdrawal aid14 can have any suitable length and/or the withdrawal aid 14 can be dyedand/or treated with an anti-wicking agent, such as wax, before beingsecured to the pledget 12.

FIG. 29 provides a non-limiting illustration of an embodiment of amethod of manufacturing a blank 28 of the present disclosure. A nonwovenribbon 32 which can have an absorbent structure 34, can ultimatelyresult in a blank 28. In an embodiment, the absorbent structure 34 ofthe nonwoven ribbon 32 can be a single layer. In an embodiment, theabsorbent structure of the nonwoven ribbon 32 can be multi-layered. Theabsorbent structure 34 of the nonwoven ribbon 32, can be manufacturedvia a multi-bank laydown process, a process whereby pre-formed fibrousmaterial layers are bonded together, or a combination thereof. Duringthe manufacture of the absorbent structure 34 of the nonwoven ribbon 32,the absorbent structure 34 can have any configuration of layers asdesired. During the manufacture of a multi-layered absorbent structure34 of a nonwoven ribbon 32, the layers can be configured into anydesired configuration, such as, but not limited to, the configurationsdescribed and illustrated herein. The nonwoven ribbon 32 illustrated inFIG. 29 can have an absorbent structure 34 which can have two layers, 36and 38, which can be placed into communication with each other. In anembodiment, the two layers, 36 and 38, can be bonded to each other afterthey are placed into communication with each other. Each of the layers,36 and 38, can have transverse edges, such as transverse edges 48 and 50of layer 36 and 64 and 66 of layer 38. In the non-limiting illustrationof FIG. 29, transverse edge 50 of first layer 36 can be substantiallyaligned with transverse edge 66 of second layer 38. As illustrated inthe non-limiting illustration of FIG. 29, the first layer 36 can have afirst length 44 which can be longer than a second length 60 of secondlayer 38. As noted herein, the two layers, 36 and 38, can be arrangedinto any desired configuration including, but not limited to, any of theconfigurations described and illustrated herein. As described herein, atleast one slit 96 can be incorporated into at least one of the layers,36 and/or 38, forming the absorbent structure 34 of the nonwoven ribbon32. The slit(s) 96 can be incorporated into at least one of thelayer(s), such as layer(s) 36 and/or 38, prior to, after, or whileplacing one of the layers of the absorbent structure 34 intocommunication with another layer of the absorbent structure 34. In thenon-limiting illustration of FIG. 29, the slit(s) 96 can be associatedwith a transverse edge of one of the layers, 36 and/or 38, such astransverse edge 48 of layer 36. As described herein, in an embodiment,at least one slit 96 can be incorporated into at least one of thelayers, 36 and/or 38, in such a configuration so as to not be associatedwith one of the transverse edges of either of the layers, 36 and/or 38.In the non-limiting embodiment illustrated, a first layer 36 having twotransverse edges, 48 and 50, can be provided and a plurality of slits 96can be associated with transverse edge 48 to form at least one contactelement 88. As discussed herein, in an embodiment, a contact element 88can be associated with any of the transverse edges or can be locatedbetween the transverse edges of a layer. As illustrated in thenon-limiting embodiment shown in FIG. 29, the contact elements 88 can beassociated with transverse edge 48 of layer 36. The nonwoven ribbon 32can also be provided with a cover 138 and a withdrawal aid 14. As notedabove, to create a blank 28, the nonwoven ribbon 32 can be separatedinto individual units of fleece 30. The separation of the nonwovenribbon 32 into individual units of fleece 30 can occur by any suitablemethod such as stretching, perforating, or cutting such as with the useof a die cutter or a knife cutter, and the like. As illustrated in FIG.29, the nonwoven ribbon 32 can be provided with perforation cuts 140which can facilitate the separation of the nonwoven ribbon 32 intoindividual units of fleece 30. The cover 138 can be provided to thenonwoven ribbon 32 before the nonwoven ribbon 32 has been separated intoan individual unit of fleece 30 and can be provided in such a way as tospan at least a portion of the perforation cuts 140.

As noted above, the nonwoven ribbon 32 can be separated into individualunits of fleece 30 which can be rolled, stacked, folded or otherwisemanipulated into blanks 28 before the blanks 28 are formed into pledgets12. For example, suitable menstrual tampons may include “cup” shapedpledgets like those disclosed in U.S. Publication No. 2008/0287902 toEdgett and U.S. Pat. No. 2,330,257 to Bailey; “accordion” or “W-folded”pledgets like those disclosed in U.S. 6,837,882 to Agyapong; “radiallywound” pledgets like those disclosed in U.S. Pat. No. 6,310,269 toFriese; “sausage” type or “wad” pledgets like those disclosed in U.S.Pat. No. 2,464,310 to Harwood; “M-folded” tampon pledgets like thosedisclosed in U.S. Pat. No. 6,039,716 to Jessup; “stacked” tamponpledgets like those disclosed in U.S. 2008/0132868 to Jorgensen; or“bag” type tampon pledgets like those disclosed in U.S. Pat. No.3,815,601 to Schaefer.

As illustrated in FIG. 29, the fleece 30 can be radially wound into ablank 28, such as a softwind. As illustrated in FIG. 29, the nonwovenribbon 32 can be separated into individual units of fleece 30, which canundergo a radial winding process, illustrated by the partially woundunit 142, to result in a blank 28. A suitable method for making “radialwound” pledgets is disclosed in U.S. Pat. No. 4,816,100 to Friese. Theradial winding method can also include a method for forming the blankinto a pledget like that disclosed in U.S. Pat. No. 6,310,269 to Friese.Suitable methods for making “W-folded” pledgets are disclosed in U.S.Pat. No. 6,740,070 to Agyapong; U.S. Pat. No. 7,677,189 to Kondo; andU.S. 2010/0114054 to Mueller. A suitable method for making “cup”pledgets and “stacked” pledgets is disclosed in U.S. 2008/0132868 toJorgensen.

In various embodiments, the blank 28 can be formed into a pledget 12. Inan embodiment, forming the blank 28 into a pledget 12 can include acompressing step which can utilize any suitable means and apparatus. Forexample, the compressing step may utilize a plurality of dies whichreciprocate relative to one another so as to form a mold cavitytherebetween. When the blank 28 (e.g., a softwind) is positioned withinthe mold cavity, the dies may be actuated so as to move towards oneanother and compress the blank 28. The blank 28 may be compressed anysuitable amount. For example, the blank 28 may be compressed at leastabout 25%, 50%, or 75% of the initial dimensions. For example, a blank28 can be reduced in diameter to approximately ¼ of the originaldiameter. The cross-sectional configuration of the resultant pledget 12may be circular, ovular, rectangular, hexagonal, or any other suitableshape.

In various embodiments, the compressing step may not include anyadditional heat applied to the pledget 12. In other words, the blank 28can be compressed into a pledget 12 without external heat being appliedto the compression equipment or the blank 28. In various embodiments,the compressing step may incorporate or may be followed by one or moreadditional stabilization steps. This secondary stabilization can serveto maintain the compressed shape of the pledget 12. In general, thesecondary stabilization step can create hydrogen bonds between theabsorbent fibers and/or may further strengthen the entanglement of theabsorbent fibers to maintain the shape of the compressed pledget 12.

FIG. 30 provides a non-limiting illustration of an embodiment of amethod of manufacturing a nonwoven ribbon 32 of the present disclosure.A nonwoven ribbon 32 which can have an absorbent structure 34, canultimately result in a blank 28. In an embodiment, the absorbentstructure 34 of the nonwoven ribbon 32 can be a single layer. In anembodiment, the absorbent structure of the nonwoven ribbon 32 can bemulti-layered. As described herein, the absorbent structure 34 of thenonwoven ribbon 32, can be manufactured via a multi-bank laydownprocess, a process whereby pre-formed fibrous material layers are bondedtogether, or a combination thereof. During the manufacture of theabsorbent structure 34 of the nonwoven ribbon 32, the absorbentstructure 34 can have any configuration of layers as desired. During themanufacture of a multi-layered absorbent structure 34 of a nonwovenribbon 32, the layers can be configured into any desired configuration,such as, but not limited to, the configurations described andillustrated herein. The nonwoven ribbon 32 illustrated in FIG. 30 canhave an absorbent structure 34 which can have two layers, 36 and 38,which can be placed into communication with each other. In anembodiment, the two layers, 36 and 38, can be bonded to each other afterhaving been placed into communication with each other. Each of thelayers, 36 and 38, can have transverse edges, such as transverse edges48 and 50 of layer 36 and 64 and 66 of layer 38. In the non-limitingillustration of FIG. 30, transverse edge 50 of first layer 36 can besubstantially aligned with transverse edge 66 of second layer 38. Asillustrated in the non-limiting illustration of FIG. 30, the first layer36 can have a first length 44 which can be longer than a second length60 of second layer 38. As noted herein, the two layers, 36 and 38, canbe arranged into any desired configuration including, but not limitedto, any of the configurations described and illustrated herein. In thenon-limiting embodiment illustrated, a fold 110 can be incorporated intofirst layer 36. The fold 110 can bring transverse edge 48 of layer 36into communication with transverse edge 64 of layer 38. As discussedherein, additional folds can be incorporated into the absorbentstructure 34 as desired and into any configuration as desired. Asdescribed herein, at least one slit 96 can be incorporated into at leastone of the layers, 36 and/or 38, forming the absorbent structure 34 ofthe nonwoven ribbon 32. The slit(s) 96 can be incorporated into at leastone of the layer(s), such as layers 36 and/or 38, prior to, after, orwhile placing one of the layers of the absorbent structure 34 intocommunication with another layer of the absorbent structure 34. In thenon-limiting illustration of FIG. 30, the slit(s) 96 can be associatedwith the fold 110 of first layer 36. As illustrated in FIG. 30, aplurality of slits 96 can be associated with the fold 110 of first layer36 to form at least one contact element 88. As discussed herein, in anembodiment, a contact element 88 can be associated with any of thetransverse edges, a fold, or can be located between the transverse edgesof a layer. As described herein, in an embodiment, at least one slit 96can be incorporated into at least one of the layers, 36 and/or 38, insuch a configuration so as to not be associated with one of thetransverse edges of either of the layers, 36 and/or 38. The nonwovenribbon 32 can also be provided with a cover 138 and a withdrawal aid 14.As noted above, to create a blank 28, the nonwoven ribbon 32 can beseparated into individual units of fleece 30. The separation of thenonwoven ribbon 32 into individual units of fleece 30 can occur by anysuitable method such as stretching, perforating, or cutting such as withthe use of a die cutter or a knife cutter, and the like. As illustratedin FIG. 30, the nonwoven ribbon 32 can be provided with perforation cuts140 which can facilitate the separation of the nonwoven ribbon 32 intoindividual units of fleece 30. The cover 138 can be provided to thenonwoven ribbon 32 before the nonwoven ribbon 32 has been separated intoan individual unit of fleece 30 and can be provided in such a way as tospan at least a portion of the perforation cuts 140.

As illustrated in FIG. 30, the fleece 30 can be radially wound into ablank 28, such as a softwind. As illustrated in FIG. 30, the nonwovenribbon 32 can be separated into individual units of fleece 30, which canundergo a radial winding process, illustrated by the partially woundunit 142, to result in a blank 28. As described herein, in variousembodiments, the blank 28 can be formed into a pledget 12.

In various embodiments, the pledget 12 may be subject to furtherprocessing to result in a finished tampon. For example, the pledget 12may be joined with a withdrawal aid 14, such as described herein, and/orapplicator.

The withdrawal aid 14 may be attached to the pledget 12 in any suitablemanner. For example, an opening can be formed through the pledget 12(and cover 138 if provided) so as to provide a means for attaching awithdrawal aid 14. In various embodiments, the withdrawal aid 14 can beattached to the fibrous material before or after it is compressed intothe pledget 12. The withdrawal aid 14 can be attached to the fibrousmaterial and then looped upon itself. As illustrated in FIGS. 29 and 30,the withdrawal aid 14 can be associated with the nonwoven ribbon 32 andcan further be associated with the fleece 30. In such an embodiment, thewithdrawal aid 14 can be, as illustrated, wound with the fleece 30 inthe formation of a blank 28. A knot 144 can then be formed near the freeends of the withdrawal aid 14 to assure that the withdrawal aid 14 doesnot separate from the fibrous material. The knot 144 can also serve toprevent fraying of the withdrawal aid 14 and to provide a place or pointwhere a woman can grasp the withdrawal aid 14 when she is ready toremove the tampon 10 from her vagina.

In various embodiments, the tampon 10 may also include one or moreadditional features. For example, the tampon 10 may include a“protection” feature as exemplified by U.S. Pat. No. 6,840,927 to Hasse,U.S. 2004/0019317 to Takagi, U.S. Pat. No. 2,123,750 to Schulz, and thelike. In some embodiments, the tampon 10 may include an “anatomical”shape as exemplified by U.S. Pat. No. 5,370,633 to Villalta, an“expansion” feature as exemplified by U.S. Pat. No. 7,387,622 to Pauley,an “acquisition” feature as exemplified by U.S. 2005/0256484 to Chase,an “insertion” feature as exemplified by U.S. Pat. No. 2,112,021 toHarris, a “placement” feature as exemplified by U.S. Pat. No. 3,037,506to Penska, or a “removal” feature as exemplified by U.S. Pat. No.6,142,984 to Brown.

In the interests of brevity and conciseness, any ranges of values setforth in this disclosure contemplate all values within the range and areto be construed as support for claims reciting any sub-ranges havingendpoints which are whole number values within the specified range inquestion. By way of hypothetical example, a disclosure of a range offrom 1 to 5 shall be considered to support claims to any of thefollowing ranges: 1 to 5; 1 to 4; 1 to 3; 1 to 2; 2 to 5; 2 to 4; 2 to3; 3 to 5; 3 to 4; and 4 to 5.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this written document conflicts with any meaning or definitionof the term in a document incorporated by references, the meaning ordefinition assigned to the term in this written document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method of manufacturing a pledget, the methodcomprising the steps of: a. providing a first layer of fibrous material;b. providing a second layer of fibrous material; c. placing the firstlayer and the second layer into communication with each other to createan absorbent structure; d. incorporating at least two contact elementsinto at least one of the first layer and the second layer to form acontact element; e. forming the absorbent structure into a pledget. 2.The method of claim 1 further comprising the step of forming a nonwovenribbon comprising the first layer and the second layer.
 3. The method ofclaim 2 further comprising the step of separating at least oneindividual unit of fleece from the nonwoven ribbon.
 4. The method ofclaim 3 further comprising the step of rolling, stacking, or folding theindividual unit of fleece.
 5. The method of claim 1 further comprisingthe step of incorporating a fold into at least one of the first layerand the second layer of fibrous material.
 6. The method of claim 1wherein the step of placing the first layer and the second layer intocommunication with each other further includes the step of bonding thefirst layer and the second layer to each other.
 7. The method of claim 1further comprising the step of providing a cover.
 8. The method of claim1 wherein the first layer has a first transverse edge and a secondtransverse edge and the second layer has a first transverse edge and asecond transverse edge.
 9. The method of claim 8 wherein the step ofplacing the first layer and the second layer into communication witheach other further comprises the step of aligning one of the firsttransverse edge and the second transverse edge of the first layer to oneof the first transverse edge and the second transverse edge of thesecond layer.
 10. The method of claim 1 wherein the step ofincorporating at least two contact elements further comprises the stepof at least partially separating the at least two contact elements. 11.The method of claim 10 wherein the at least two contact elements areseparated by a slit.
 12. The method of claim 10 wherein the at least twocontact elements are separated by an amplitude of an arc.
 13. The methodof claim 8 wherein the step of incorporating at least two contactelements further comprises the step of associating at least one of thetwo contact elements with at least one of the first and secondtransverse edges of at least one of the first layer and the second layerof fibrous material.
 14. The method of claim 8 wherein the step ofincorporating at least two contact elements further comprises the stepof incorporating at least one of the contact elements at a locationbetween at least one of the first and second transverse edges of atleast one of the first layer and the second layer of fibrous material.15. The method of claim 5 wherein the step of incorporating at least twocontact elements further comprising the step of associating at least oneof the contact elements with the fold.
 16. The method of claim 1 whereinthe step of forming the absorbent structure into a pledget furtherincludes the step of compressing the absorbent structure.
 17. A methodof manufacturing a nonwoven ribbon, the method comprising the steps of:a. providing a first layer of fibrous material; b. incorporating atleast two contact elements into the first layer of fibrous material; c.providing a second layer of fibrous material; and d. placing the firstlayer of fibrous material into communication with the second layer offibrous material.
 18. The method of claim 17 further comprising the stepof incorporating a fold into at least one of the first layer and thesecond layer of fibrous material.
 19. The method of claim 18 wherein thestep of incorporating the at least two contact elements furthercomprises the step of associating at least one of the contact elementswith the fold.
 20. The method of claim 17 wherein the step ofincorporating at least two contact elements further comprises the stepof incorporating at least one slit into at least one of the first layerand the second layer of fibrous material.